Value Stream Mapping

by

Best Performing Consulting Organization

Adding Value In Totality !!

Learning Framework
1. Introduction
2. The Current State Map
3. Lean Value Stream
4. The Future State Map
5. Achieving the Future State
6. Conclusion
2

Value Stream Mapping

Purpose :
1. Introduce Value Stream
Mapping in a hands on
manner.
2. Develop your ability to
see

the

flow

and

design future state value

streams.
3

VALUE-STREAM IMPROVEMENT
and PROCESS IMPROVEMENT
VALUE STREAM
PROCESS

Stamping

Raw
Material

The Three Value Streams:

PROCESS

Welding

PROCESS

Assembly
Cell
Finished
Product

Raw Material to Finished Product

Concept to Launch
Order to Cash
4

Value Stream Mapping

Follow a products production path from beginning
to end, and draw a visual representation of every
process in the material & information flow.
Then, draw (using icons) a future state map of
how value should flow.

Using the Value Stream Mapping Tool

Product Family

current state
drawing
future state
drawing

Understanding how the shop

floor currently operates. The
foundation for the future state.
Designing a lean flow.

plan and
implementatio
n

Focus on One Product Family

Determine Product Families via :
Similar downstream assembly steps and equipment
Process Steps & Equipment
Spot
Weld

Robot
Weld

Flash
Remove

Paint

Manual
Assm.

Fixtures
Assm.

Electronic
Test

PRODUCTS

LH Steering
Bracket
RH Steering
Bracket
Instrument
Panel Brace
Seat
Rail
Bumper
Brackets

Levels of a Value Stream

Process level
Mapping level to start

Single plant
(door to door)

Multiple plants

Across companies
9

Learning Framework
1. Introduction & Getting Started
2. The Current State Map
3. Lean Value Stream
4. The Future State Map
5. Achieving the Future State
6. Conclusion
10

Time
Push

Current-State Map
showing the Customer

11

Team Tips
Current State Mapping
1. Mapping the current state :
Review the basic processing steps and calculate the takt time in
your teams breakout room.
Everyone draw while on the shop floor.
Be sure to draw both the material & information flows.
Always introduce yourself to operators and tell them what you are
doing : Drawing the total factory flow as part of a training
session. Show them your drawings.
Select a scribe and combine your drawings into one current state
map (in team area).
Calculate total lead time versus processing time.
Make an overhead transparency of the map and select presenters.
12

Team Tips
Current State Mapping
2.

Presenting your

All team members go up front with presenter. State the product

family and takt.

Present from your overhead transparency. (Less than 5 minutes.)

Start with the customer and information flow into the facility.

State the lead time vs. processing time.

What are the problems you see? Where did you find push and
overproduction ?

Share any future state thoughts you have so far.

13

Value Stream Loops

14

Load-leveling box
Kanban are responded to from left to right at pitch
increment
One row per
product
type

One column per pitch here pitch = 10 min

Kanban
15

An Example of Paced Withdrawal

16

ADDVALUE Services
VALUE ADDED COACHINGVAC
BUSINESS COACHING

LIFE COACHING

Operation
Excellence

Counsellin
g

Team
Excellence

Therapy

Business
Excellence

Adding Value In Totality !!

Astrology

AddValue at a glance
Best Performing Consulting Organization

Business Coaching

Life Coaching

Thank You