AGENDA,Complete Vision statement Presentation On Value Stream Mapping Exercise “Learn By Doing” Select Process & Process Teams Set next review meeting.,Value Stream Mapping,Duracell - Lean Manufacturing Initiative,Value Stream Mapping,What is a Value Stream ? What is Value Stream mapping ? Why the need for mapping ? How does it benefit us ? How the Value Stream is mapped. How to get involved.,What Is A Value Stream ?,The value stream is the set of specific processes or steps taken that are required to produce a product or service by any business. It includes information management tasks such as order taking, planning, scheduling as well as physical operations such as manufacturing, testing and shipping.,What Is Value Stream Mapping ?,Manufacturing processes are the basis on which a business creates its wealth (money). Some processes add value and some are essential but dont add value, and some are simply wasteful and shouldnt happen at all. To improve the business we need to know the difference between these processes.,What Is Value Stream Mapping ?,Knowing the good processes and wasteful processes allows us to develop a plan for improvement. An effective way to know the difference between good processes and bad processes is to undertake value stream mapping. “By understanding the whole process from raw material to finished product we are able to see where we can remove waste” - Wise man.,Why The Need For V/S Mapping ?,To be successful we need to continuously strive to be competitive. To be competitive we must eliminate waste and interruptions and reduce production lead times to a minimum. It is easy to make an instant cost saving, it is hard to make an ongoing saving without understanding the effect on the internal value stream.,Why The Need For V/S Mapping ?,To achieve ongoing improvement we need to understand the value stream because: Many businesses are run as a series of departmental groups rather than as a manufacturing process. Therefore fixing one piece without understanding the effect on the overall process flow will generally not improve overall business performance.,Why The Need For V/S Mapping ?,To achieve ongoing improvement we need to understand the value stream because: Efficiency is a measure of manufacturing speed, rather than as a measure of the processes and delays during manufacturing. Stock locations often exist to absorb inefficiencies and become accepted as part of the process.,Value Stream Mapping is a means to prioritise improvement activities and achieve benefits which result in real cost savings, visible service improvement and quality improvements. Value stream mapping will highlight the issues, aid effective decision making, create focus for improvement and help us work cohesively together.,How Does It Benefit Us ?,How Does It Benefit Us ?,Value stream Mapping Focuses on design of the production system. We will benefit through: Better understanding product cost Clearer picture of processes Reduction of WIP Reduction in lead times,How Does It Benefit Us ?,We will benefit through: Faster response to demand changes. Faster response to quality concerns. Reduction of inventory in DCL and with distributors. An emphasis on “pull” from the customer. An increase in value added contribution. Standardisation of the production process.,How The V/S Is Mapped,Typical Change Process (Steps) Find a change agent. Get the “knowledge”. Find a lever (reason for improvement). MAP YOUR VALUE STREAM. Make your action plan. Implement your plan.,How The V/S Is Mapped,The V/S mapping program is a structured step by step approach. It is a combination of classroom theory and “learning by doing”. The mapping activity encompasses the whole chain of events from communication with suppliers to delivery of product to the customer. The important thing is to capture all process steps in the business.,How The V/S Is Mapped,Select a product or family of products which follow similar process routes. Draft a “current state” map to reflect material flow, information flow and order of production processes. Create a future state map (teams vision of the ideal condition in which waste has been fixed). Develop an action plan with a detailed prioritised list to achieve the future state.,Get together in a small group. Pick a family of products (a family is a group of products that pass through similar processing steps and over common equipment). Use pencil and paper only. Dont try and make every single detail perfect.,How To Get Involved,Nominate one person in your group as the team leader - they are responsible for leading the mapping exercise. In the case of physical operations try walking along the actual pathways while collecting the information. Begin with a quick walk along the door-to-door value stream to get a sense of the flow and sequence of operations.,How To Get Involved,Begin mapping from the shipping end and work backwards (it avoids dead ends more effectively). Bring your watch / stop watch and time steps for