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Full Description
Providing a framework that highlights waste and its negative effects on process performance, value stream maps (VSMs) are essential components for successful Lean initiatives. While the conventional VSM format has the basic structure to effectively describe process operations, it must be adapted and expanded to serve its purpose in the process industry.This book describes in detail how to create a complete VSM for a process industry manufacturing operation. Detailing the unique features of process operations and why they require additions and adjustments to traditional VSMs, the book walks readers through the steps in analyzing the map. It explains how to scope improvement projects, prioritize them, and then use future state VSMs to illustrate and motivate systemic improvement. In doing so, it supplies readers with a roadmap for a complete Lean transformation.
Describes how to analyze the map for waste and flow issues so that they can be reduced and even eliminated
Provides examples of the calculations needed for the flow parameters in data boxes
Explains how the VSM concept can be applied to the entire supply chain
Includes strategies for engaging your entire workforce in map creation
The book introduces a target manufacturing process and uses it to describe how to create a complete VSM. The target process is complex enough to illustrate the issues often encountered in mapping a process industry operation, but straightforward enough to explain all of the mapping considerations and decisions.The book includes real examples of how VSMs brought much greater clarity to the real issues the processes faced and cases where the insight enabled management to avoid costly, inappropriate investments.
Contents
The Value of Mapping. Value Stream Mapping Fundamentals. VSM Enhancements for Process Operations. Additional Good Mapping Practices. Our Focusing Problem—A Synthetic Fiber Process. Developing the Material Flow. Calculating Data Box Parameters. Material Flow Rates and Takt. Completing the Data Boxes: Utilization, Delivery Frequency, and Days of Supply. Mapping the Information Flow. Developing the Timeline. Finding the Waste—Analyzing the Map. Scoping the Opportunities. Implementation Strategy and Sequence. Future State Value Stream Maps. Supply Chain Mapping. VSM as a Way of Engaging Employees. A Roadmap for Continuous Improvement. Benefits of Developing a VSM.
