Value Stream

Mapping

Manufacturing Excellence
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What is Value Stream Mapping

"Value Stream Mapping (VSM), is a

Lean Manufacturing technique to
analyze, design, and manage
the flow of materials and
information required to bring
a product to a customer''

Visualizing Flow

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 VSM Symbols

Material Flow Icon Information flow & General Icon

Outside source Inventory Box Electronic Info. flow Kanban Post

Data Box Truck Shipment Schedule Kanban Arriving in batch

Operator Super Market Load Leveling Sequenced Pull Ball

Process Frist in Frist Out Withdrawal Kanban Go See

Push Arrow Production Kanban Kaizen Burst

FG to customer

Signal Kanban Safety Stock

Physical Pull
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 Lean Measurements
TAKT TIME
Takt time is the rate at which you need to complete a product
in order to meet customer demand.

Example :
Coffee shop Every hour Customer placed 6 cup coffee order
Takt Time = Available time / Customers demand
Takt Time ( Coffee shop ) = 60 min / 6 cup = 10 Min takt time for every cup order

CYCLE TIME
The cycle time is the amount of time it takes to complete a specific task from
start to finish.

Example: Coffee making personnel spend 8 min for each cup

For fullfed customer demand Cycle time is always less then Takt time

Lead time is the amount of time between when a customer places an order and
LEAD TIME when the customer receives the product.

Example:
Pre-processing time - Transfer order details (45 sec )
Processing time - For preparation coffee ( 8 Min )
Post Processing time - Delivery time to costumer ( 1 Min )

Lead Time = (Pre-processing time + Processing time +Post Processing time)

Lead Time (Coffee Shop) = 45 Sec. + 8 Min. + 1 Min = 9 Min 45 Sec.

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 VSM Steps

Step 1 Build team and hold VSM event

Step 2 Identify, Collect data of the Strategic

stream

Step 3 Map the Current state

Analyze wastes & bottlenecks in the

Step 4 Current state

Step 5 Discuss, Create the Future state map for

achieving Organization goals

Implement the action plan & review

Step 6 periodically

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 Current State Mapping

Data Required for Mapping:

C/T (Cycle time)

C/O (Changeover time )

Uptime ( On-demand machine uptime)

Demand rate, Takt time

Production batch sizes

Number of operators

Product variety, batch size

Standard & In process Rejection

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 Draw Current
State Mapping
Step 1: View of Current state map
showing the customer

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 Draw Current
State Mapping

Step 2: View of Current state map with all

Processes, Data boxes, and Inventory
triangles

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 Draw Current
State Mapping
Step 3: View of Current state mapping showing
the material flow

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 Current State
Mapping View
Step 4: View of the Current state map with
information flows & push arrows

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 Current State
Mapping View
Three key sections of value stream map

Information flow

Material flow

Lead time ladder

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 Improvement Points for
Value Addition

1 2 3 4
Align Develop Use
production Continuous supermarket to
Produce as per
planning with flow wherever maintain
takt time
customer possible uninterupted
demand production

5 6 7
Use Andon , Visual Identify Develop the ability
Controls to bottleneck to make every part
highlight process , do every time in any
abnormality improvements processes
occurance in to streamline upstream of the
production flow process
operations

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Future State
Map View

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 BENEFITS OF VSM

Identify
Waste
Improve Cross-
Functional
Collaboration
Identify
Bottlenecks
Streamlined
Process
Improve end-
Product Quality
Ontime, In Full
Deliveries
Reduce
Cost

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