How to identify waste in your organization that is eating your benefit? Answer: VSM (Value Stream Mapping)

VSM, Value Stream Mapping

What is VSM?

VSM is a graphical technique that can visualize an entire process, allows detailing and fully understand the flow of both information and materials needed to make a product or service reaches the customer, this technique activities that do not add value to the process to identify then initiate the necessary activities to eliminate them, VSM is one of the techniques used to establish improvement plans to be very accurate because it focuses improvements in the process point of which the best results.

How implements a VSM?

Proceso-de-implementacion-de-un-VSM
Implementation process of a VSM

To perform a VSM must perform a series of steps that systematically described below.

1) Identify the product family drawing
To identify a product family can use a product-process matrix, considering that “A product family are those who share time and equipment, as they pass through the process.”

Once the matrix should look like the following:
Product matrix process
In this matrix 2 families, machines / equipment or operations that belong to each family should be grouped to start training for product flow and to implement tools like SMED, Kanban, etc. are identified And especially to reduce in-process inventory.

2) Draw the current state of the process by identifying inventories between operations, material and information flow.

At this stage, should the lifting of the current VSM, which shows the flow of information and product flow, usually when not implemented Lean Manufacturing obtained maps look like the following example.

Current VSM: Example of VSM Current

VSM-Actual
3) Analyze the vision of what should be the future state.
This happens is all the more complicated because it requires experience to design the future state in many Lean tools like Kanban, SMED, Kaizen.

At this stage must be set to work the process in the short term, must be analyzed and answer the questions what processes are integrated?, How many operators require line ?, how many teams ?, What space? and how much the stock in process?

The Takt Time (TT) is calculated by dividing the opening time low less per day between the quantity of parts to be produced per day times.

The Lead Time (LT) is the sum of all dead times shown in red in the example.

Content of work (WC), is the time in which it is printed value to the product is the sum of the times in green example.

The amount of required operators is calculated by dividing the work content (WC) between the Tack time (TT).

4) Draw the future VSM
VSM Future: VSM Objective or future

VSM-Futuro1
The purpose of the Value-Stream Map (VSM) is to highlight the sources of waste, so the implementation of this future should be done in a short period of time, the goal is to build processes that are associated with customers, working Tack time , continuous and pulled by the client (Pull) flow.

In the VSM must be identified:
• Identify process bottle neck
• Identify where waste products
• Identify where resources (both men and machines) are wasted and
• Define inventory Max and min., Identify the cause of these stocks
• Identify appropriate solutions to eliminate them.
• Identify which flow should be pushed and pulled and which consequently disrespected by the FIFO.

5) Record action plan and implement actions
To get to the future state, changes should be made which should be reflected in an action plan, track to reach the future state, once reached this state, the process starts again to achieve operational excellence that many companies pursue daily.

 

 

How to identify waste in your organization that is eating your benefit? Answer: VSM (Value Stream Mapping)

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