Value stream mapping is one of the lean manufacturing concepts and is widely used to optimize processes in industries. The main purpose to implement a value stream mapping tool is to create a future vision toward operation excellence with current process mapping. During value stream mapping implementation many lean manufacturing tools and concepts have been used to improve the process. Material flow and information flow management are very important criteria during VSM implementation.
During value stream mapping implementation key target areas are bottleneck processes, cycle time analysis, material and information flow, FIFO, inventory control, lead time, process efficiency, productivity, space utilization, process layout, and process waste.
Content
• Key objectives for implementing VSM.
• What are the approach for VSM implementation?
• Practical VSM implementation steps.
Phases of value stream mapping
Current state map
The current state map is a basic replication of the current process on paper. On a general basis, the basic approach of VSM implementation is reducing overall lead time and inventory level. Collect the operational data, inventory data, material and information flow data, process sequences, process-wise manpower, value-added and non-value-added time, process or equipment utilization, financial data such as cost per unit, etc.
Idea generation
In the idea generation part, data analysis is very important. Based on data collection, identify the bottleneck of processes and target areas for future improvement. Review below attached key objectives for VSM and create a roadmap for VSM implementation.
Three things are very important for idea generation as per mention below.
- Understanding current process.
- Identify opportunity for improvement and major gaps.
- List down numbers of the possible ideas to improved process with the help of brainstorming.
Future state mapping
Future state mapping is a basically implement the proposed plan as per roadmap. This is the very difficult step in value stream mapping because paper plan and actual implementation both are different things. In this stage handle the practical issue during layout or process modification such as convince people for change and many more.
Result review
The very important phase in VSM is the result review stage.Monitoringr the outcomes and theirs variations as per plan is very important. Review the major gap availability of the actual process compared with the planned one. Review the line balancing issues and make a rigid plant minimizing the variation across between workstations at ground level.
What are the key objectives for implementing the VSM project?
- Manufacturing lead time and customer order cycle time reduction.
- Inventory reduction. (raw material, work-in-progress and finished goods)
- Manpower optimization.
- Space optimization.
- Minimize material and interdepartmental movement of operational processes.
- Process layout modification with modified workstation layout.
What is the approach for VSM implementation?
There are three approaches for value stream mapping implementation as per the below attached. All the approach is described based on industrial application.
- Internal Implementation: – Internal VSM implementation approach is applied in within industries scope. Consider the operational process from raw material receiving to finished material dispatch. In this approach majority of activity are controlled by organizational or industries level.
- External Implementation: – In external VSM implementation approach is applied out of industries scope. In this approach majority of activity not controlled by organizational level but organization is depending on such activity like suppliers, customers, vendors and many more.
- Internal & External Implementation: – This approach is also called as combined approach. In this approach working scope is within organization level as well as out of organizational level. For perfect implementation developed team for internal and external activities.
Practical VSM implementation steps
- Data collection of the operational process with process sequence map as well as information and material flow.
- Data compilation and data analysis.
- Identify the bottleneck of the process.
- Identify the scope of work based on selecting an implementation approach.
- Define objectives for VSM implementation and decide target for improving operational parameters.
- Idea generation – review process and identify one-piece flow implementation, minimize material handling with a compilation of processes, make different layout options based on brainstorming, identify waste minimization possibilities, target for minimizing motion of manpower, and many more.
- Choose the final layout option for implementation as per top management guidelines.
- Layout modification and implement changes as per plan.
- Train the performer for the updated process.
- Collect the data after future state implementation.
- Review variance between planned and actual.
- Make a list of opportunities for improvement and major planned versus an actual variation.