Lean Manufacturing -
Value Stream Mapping
Wenqin Shao, MBA, P.Eng.
President
Sino Waypoint Consulting Inc.
[email protected]
Sino Waypoint Consulting Inc.
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Lean Manufacturing
• The Fundamental Insight & Objective
• Shift the focus of management from
existing organization, technologies, and
assets to the product!
• Differentiate value from waste
• Enhance value and remove waste by
looking down, not up!!!
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Summary
• Accurately specify value by product
• Identify the value stream
• Make the product flow
• At the pull of the customers
• In pursuit of perfection
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Benefits
• Dramatically reduce costs of manufacture
• Improving labour utilization;
• Decreasing inventories;
• Reducing manufacturing cycle times
(from order receipt to shipment);
• Increasing capacities without capital
expenditure.
Sino Waypoint Consulting Inc.
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Achievements Improvements in direct &
indirect labour utilization
Increases in capacity in
current facilities 10%
10%&&50%
50%up
up
30%
30%&&up
up
50%
50%or
orgreater
greater Lean
Lean
Manufacturing
Manufacturing Improvement
productivity
70%
70%or
ormore
more 50%
50%or
orgreater
greater
Decreases in
manufacturing cycle Reductions in
times inventories
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Major Process Steps
Next Steps Of
VSM Practice
Implementing The
Future VSM Process
Mapping A Future
Value Stream Process
Begin By Mapping
The Existing Processes
Value Stream
Mapping
Self Assess Current
Manufacturing Process
Sino Waypoint Consulting Inc.
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Assessment Radar Chart
1. Operation Strategy
2. Layout & Material
Handling
3. Quality Control
4. Visual Management
5. Team Approach
6. Staff flexibility
7. Cells and lines
8. Processes
9. Inventory
10.Setup
11.Maintenance
12.Suppliers
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Implementing Process
1. Begin by mapping the existing
processes
2. Segment products into families
3. Using process flow chart
4. Review material handling process
5. A great deal of discipline of instill in the
cell team
6. An effective lean design utilizes a high
level of visual control
7. Select and use measures to gauge
project results
8. Implement the project using tracking
tools.
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Five Major Work Steps
Results
Evaluation
Reconfiguration
& Implementation
Create a future
Value Stream Map
Mapping
current process
VSM
process train
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The VSM Team
Project Sponsor
Project
Project
Sponsor
Sponsor
VSM
VSMteam
team
Coordinators
Coordinators
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VSM Timing
Elapsed Days
Major Worksteps
1 2 3 4 5 6 7 8
1. Participate in extensive Lean Manufacturing
training session
2. Principal of Lean Manufacturing Theory and
one piece flow concepts
3. Mapping current manufacturing process
4. Review process flow, create Future Value
Stream Map
5. Workcell Design and Lean Manufacturing
plant layout design
6. Reassessment and evaluation achievements
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A Results VSM
w Interpret results
w Apply the conclusions
w Provide greater insights
w Discuss implications
w Identify key areas of
improvement opportunity
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Lean Manufacturing Grid
Company’s
High Key Drivers Score
Value
World w Operation Strategy 1
1
Value Class w Layout and Material Handling
w Visual Management 2
“Value-added to
w Team Approach 1
eliminate waste”
w Setup 2
Company w Suppliers 2
Total Score 9/30
Efficiency
w Cells and Lines 3
w Quality Control 4
Low Efficiency High
w Staff Flexibility 2
“Leveraging process to
streamline operations” w Processes 5
w Inventory 3
w Maintenance 4
Total Score 21/30
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Managing Toward Perfection
Next Future State
Future State
Current State Original State
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Practices & Opportunities
Annual Best Practices Conference
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Consulting Packages
One day package
• Principles & Lean Strategy
Current Process Assessment
The Lean Practice
Lean Strategy Development
Two days package (include day one package)
• Current Manufacturing Map
Kanban Design
Lean Scheduling
Cycle Counting
Rapid Setup
Five days package (include day one and two package)
• Future Value Stream Map
Lean Process Layout
Workcell Design
Future value stream map practice
Special Consulting package
• Kaizen blitz / 5S / Team building / Pull system
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Contact Information
Lean Manufacturing consulting Project
Contact:
Wenqin Shao
[email protected]
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