P.O. Box 9 Brookline MA 02446

P (617) 713-2900

Value Stream Mapping Workshop F (617) 713-2999

______

Description:

Value-stream maps are the blueprints for lean transformations. This workshop shows you how to make and apply this fundamental and critical tool, based on the Institute's groundbreaking value-stream mapping workbook, “Learning to See,” which has introduced the mapping tool to thousands of your colleagues around the world.

The value-stream map is a paper-and-pencil representation of every process in the material and information flow, along with key data. It differs significantly from tools such as process mapping or layout diagrams because it includes information flow as well as material flow.

Mapping is a critical initial step in lean conversions because it shows you where to apply lean techniques for maximum effect – as part of lean value streams. You’ll avoid the common mistake of cherry-picking lean techniques, which leads to building isolated islands of improvement instead of improving the whole production flow to reap the biggest benefits.

Working with a simple factory example, you’ll learn how to see value, differentiate value from waste, and eliminate the sources of waste by creating accurate current-state maps and leaner future-state maps for each of your product families along with implementation plans for achieving the future state.

The benefits of mapping include:

  • Targeting kaizen activities for bigger and more sustainable impact
  • Gaining a better understanding of the linkages between material and information flow
  • Visualizing improvements to the overall production flow, instead of spot improvements to single processes
  • Seeing beyond waste to the sources of waste
  • Creating the basis of an effective lean implementation plan by designing how the door-to-door material and information flow should operate
  • Giving operators, engineers, and managers a common language of continuous improvement

This workshop assumes you are familiar with basic lean concepts as described in “Lean Thinking” by James Womack and Dan Jones. You can enhance the educational experience by developing a value-stream perspective before attending the workshop by reading “Learning to See” by Mike Rother and John Shook.
We'll come to you! Call 617 713-2900 to ask about bringing this workshop to your facility.

Curriculum:

Using a simple factory example, participants will learn how to identify a product family, how to see the entire value stream for a particular product family, how to map the value stream to identify and eliminate waste, what makes a value stream lean, and how to develop a plan to achieve immediate results. Workshops contents include:

 Value-stream improvement vs. process improvement

 Focusing on a product family

 The value-stream manager

 Levels of a value stream

 Case study data set

 Exercise: Drawing a current-state map

 What is a lean flow?

 Individual efficiency vs. system efficiency

 Takt time

 Build to supermarket or to shipping?

 Continuous flow processing

 Scheduling one point

 Mixed production at the assembly pacemaker process

 Paced withdrawal at the pacemaker process

 Designing a lean flow

 Exercise: Drawing a future-state map

 How to create a plan for implementing the future state
By implementing the lessons learned, participants' organizations will be able to:

 Improve cross-departmental communication

 Identify and eliminate the sources of waste

 Free resources

 Increase productivity

 Achieve immediate and sustainable results

 Improve bottom-line performance

- 1 -