精益生產(chǎn)之價值流圖Value-Sream-Maing

ValueStreamMappingAgendaMondayKick-OffIntroductionsCurrentStateSteps1-4TuesdayCurrentStateSteps5-7WednesdayCurrentStateSteps8-9IdentifyandPrioritizeImprovementOpportunitiesCreateFutureStateThursdayPrepareforPresentationPresentation2LearningObjectivesThelearningobjectivesforthiscourseare:BeabletocreateCurrentStateandFutureStateValueStreamMapsBeabletousecustomerandbusinessrequirementstoprioritizeimprovementopportunitiesThelearningobjectiveforthiscourseisnot:ToteachLeanToolstohelpachieveFutureState3What’sinItforMe?Valuestreammappingisavisualtooltohelpunderstandthecurrentvaluestream.Itallowspeopletoeasilyunderstandwherewasteexistsintheprocess.Itgivestheteamabasisforprioritizingimprovementefforts.Itgivestheteamavisualtoolforrepresentingtheirimprovementideas,sotheyarebetterabletocommunicatewithpeopleinsideandoutsidetheorganization.4TeachingApproachTeachappropriateValueStreamMappingstepShowsimplifiedexampleShowcomplexrealworldexampleWorkB&DIndustriesExerciseinteamsApplylearningtoFlygtprocess5ValueStreamMappingProcessStepsIdentifyCurrentStateStep1:SIPOCChartStep2:TopDownFlowChartStep3:DetermineProductFamilyStep4:DrawProcessFlowStep5:DrawMaterialFlowStep6:DrawInformationFlowStep7:ProcessDataCollectionStep8:AddProcessandLeadTimedataStep9:VerifyCurrentStateMapIdentifyandPrioritizeImprovementOpportunitiesDetermineFutureStateImplementImprovementstoAchieveFutureState6ValueStreamManagerAssignValueStreamManagerOnepersontomanagethemappingofthetotalflowHasthecapabilitytomakechangesacrossdepartmentalboundariesLeadsthecreationandprioritizationoftheimplementationplanforgettingfrompresentstatetofuturestateMonitorsimplementationandupdatesimplementationplanDriverforresults7CurrentStateVSM8Production

ControlASSEMBLY20,000pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachineRawmaterialDailyscheduleForgematerialDailyschedule

Bolts,nuts,washersDailyscheduleO-ring,bearing,snapringDailyschedule

WarehouseReceiving6MonthForecastWeeklyFaxMRP90/60/30DayDailyOrderDailyRelease2/Day1/WeekCustomerC/T=30SecC/O=30MinUptime75%Batch

Size100C/T=45SecC/O=60MinUptime95%BatchSize100C/T=60SecC/O=5MinUptime95%BatchSize100C/T=50SecC/O=10MinUptime95%BatchSize1001000pcs5000pcs100pcs200pcs30sec60sec45sec50sec15hours83hours2hoursProcessingtime=185seconds4hoursProductionleadtime=104hours3min8FutureStateVSM9Production

ControlASSEMBLY20,000pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachine

WarehouseReceiving6MonthForecastDailyOrder90/60/30DayDailyOrder2/DayDailyCustomerC/T=30SecC/O=30MinUptime95%Batch

Size100C/T=45SecC/O=10MinUptime95%BatchSize100C/T=60SecC/O=5MinUptime95%ModuleSize100C/T=50SecC/O=10MinUptime95%ModuleSize100200pcs500pcsMax100pcsMax200pcs30sec60sec45sec50sec2.5hours10hours2hoursProcessingtime=185seconds4hoursProductionleadtime=18hours33minSet-upReductionBatchBinDailyOrderTPMModuleFIFOFIFOMatMat1)Set-upreduction2)PullSystems3)TPM9

ValueStreamMappingSIPOCTop-DownMapValue-StreamMappingProcessMappingHierarchyOUTPUTPROCESSCUSTOMERSUPPLIERINPUTSIPOCchartTopDownProcessFlowVSMCompanyMult.PlantsSinglePlantRouterStepsProcessStepsI22I48450PerDay400MinAvail1ShiftC/T7Min180PerDay1200MinAvail3ShiftC/T3MinStep22Step31Step14300PerDay400MinAvail1ShiftC/T12Min11Step1SupplierInputProcessOutputCustomer

(SIPOC)MapStep1:High-LevelSIPOCChartSupplierInputProcessOutputChart(SIPOC)Customers:CompaniesX,Y,&ZOutputs:Cost,Quality,On-TimeDeliveryProcess:ProduceProducts1,2,3,4&5Inputs:RawMaterialSuppliers:CompaniesA,B&CAhigh-levelSIPOCcharthelpstoidentifytheprocessoutput(s)andthecustomersofthatoutputsothattheVoiceoftheCustomercanbecaptured13OUTPUTPROCESSCUSTOMERRequirements,SpecificationsandInformationSUPPLIERINPUTBoundary-(“Triggers”Process)Boundary-(ProcessCompleted)Step1:TheSIPOCChartTranslateCustomerrequirementsintooutputspecificationsandidentifyrelatedKeyProcessOutputVariables(KPOVs)GoUpsteamtotheProcessSteps(s)whichmostimpacttheOUTPUTanddeterminetheKeyProcessInputVariables(KPIVs)TrytouseLeadingMeasure(s)(insteadofLaggingMeasures–iflagging,thenClose/ReduceamountofLagging)14Step1:SIPOCBusinessRequirementsNotonlyshouldtheSIPOCchartcapturecustomerrequirements,butalsothekeyBusinessRequirementsaswell.OUTPUTPROCESSCUSTOMERSUPPLIERINPUTCustomerRequirementsQualityOn-timeDeliveryCostBusinessRequirementsReducedInventoryIncreasedThroughput15Step1SIPOCChartB&DIndustriesExerciseStep2TopDownProcessFlowStep2:Top-DownProcessFlowPurposeThepurposeoftheTop-DownProcessFlowistodeterminethecorrectleveltoValueStreamMap.Itiscriticaltoourbusinesstofocusourimprovementresourcesontheareasthataregoingtohavethegreatestreturn.WedonotwanttocreateValueStreamMapsforthesakeofcreatingprettypictures.18TheProcessTheSub-ProcessTheMicro-ProcessStep2:GenericTop-DownProcessFlow19DistributionPumpMotorFoundryExample:Step2:Top-DownProcessFlowMapStartStopD-1D-2D-3D-4D-5D-4aD-4bD-4cD-4dD-4e20Step3DetermineProductFamilytoMapStep3:DetermineProductFamilytoMapChoosetheproductfamilythathasthegreatestimpactontheCustomerOutputs,andtheBusinessRequirements.Chooseaproductfamilywithcommonflow.Chooseaproductfamilywithhighvolume.Chooseaproductfamilybasedoncustomerindustry,orotherproductsegmentation.Ifaproductfamilyisnotreadilyapparent(suchasinajobshopenvironment),useaprocess/productmatrixtoidentifyaproductfamily.22Step3:Process/ProductMatrixProductsandProcessMatrixCreateamatrixofproductsandprocesses(equipment)throughwhichtheypass.Referenceroutersifnecessarybutensuretheyareverifiedandnotassumedtobeaccurate.Groupsimilarproductstogether.23Step4DrawtheProcessFlowStep4:DrawtheProcessFlowTips:Beginattheendoftheprocess(shipping)andworkupstreamDeterminewherematerialandinformationisusedalongtheprocessMaptheentireprocessasateamtounderstandtheentireflowDrawValueStreamMapsbyhandtogetitdonequickly,andmakeiteasytochangeLessonsLearned:GetalignmentonstartandendofvaluestreambeforebeginningmapBemindfulofprocessesthatareinparallelvs.seriesCaptureallreworkloopsandinspectionstationsonthemapLimitthevaluestreamtojustoneproductfamily25Step4:SampleSymbolsMachiningProcessBoxDataBoxIInventory1OperatorManualInformationElectronicInformationC/T=36SecSetUpTime7MinUptime86%BatchSize50InspectionPointWithdrawalKanbanPushArrowCustomers/SuppliersToCustomerProductionKanbanSupermarketTruckShipmentFutureStateImprovement“GoSee””SchedulingDailyScheduleSchedule26Step4:ValueStreamMappingSheets27Step4:DrawtheProcessFlowProduction

ControlASSEMBLYCUSTOMERProduction

ControlMACHINESUPPLIERDIST28AssemblyAssemblyForgeMachineRawmaterialDailyscheduleForgematerialDailyscheduleBolts,nuts,washersDailyscheduleO-ring,bearing,snapringDailyschedule28SupplierRawMaterialsMRPtransactionReceivingInspectionReceiving1UnpackBottlesUnpack1BottleWasherWasher1Fill&CapFill1HeatShrinkSealer1LabelsonBottlesLabeler1PackProductDropPack1LabelsonPackageLabel1Tag&CratePallet1ShrinkWrap&LoadShip1DistributionCenterCustomer888Cases/Day37Cases/HrIBottleKits16daysIWarehouseIIIIStep4:ProcessFlowLiquidPharmaceuticalCurrentStateVSM29Step4DrawtheProcessFlowB&DIndustriesExerciseStep4:B&DIndustriesExerciseCompletethefollowingstepsusingtheinformationfromB&DIndustries:CurrentStateProcessFlowMaterialrequiredateachprocessstepInformationrequiredateachprocessstepTime:1Hour31Step4DrawtheProcessFlowFlygtActivity2HoursStep5DrawtheMaterialFlowStep5:DrawtheMaterialFlowShowthemovementofallmaterialusedintheValueStream.Groupmaterialwiththesameflow.Mapallsub-assemblyprocesses.Includeanyincominginspection,andmaterialtestingoperations.34Step5:DrawtheMaterialFlowProduction

ControlASSEMBLYSUPPLIERDISTAssemblyAssemblyForgeMachineRawmaterialDailyscheduleForgematerialDailyscheduleBolts,nuts,washersDailyscheduleO-ring,bearing,snapringDailyschedule

WarehouseReceivingCustomer35SupplierRawMaterialsMRPtransactionReceiving0.5111InspectionReceiving1UnpackBottlesUnpack1BottleWasherWasher1Fill&CapFill1HeatShrinkSealer1LabelsonBottlesLabeler1PackProductDropPack1LabelsonPackageLabel1Tag&CratePalletizer1ShrinkWrap&LoadShip1DistributionCenterCustomer888Cases/Day37Cases/Hr11111KitNeckRingsIBottleKits16daysIWarehouseIPowderIII1ReceivingInspectionLotSample1AnalyticalLabTesting2OffLoad0.5PurifyWaterTankCleanPrepSampleFill&MixReleaseSolutionLabInspectionReceivingLabTestTestGrind1Tumbling1IVials2hrsICaps4hrsBottleWasherWashBottleFillFillBottleCapCapKitting1RingSub-contractorIIIIIIIIBottleKits16daysIIILiquidPharmaceuticalCurrentStateVSMStep5:MaterialFlow36Step6DrawtheInformationFlowStep6:DrawtheInformationFlowMaptheinformationflowfrompurchaseorderreceipttoorderrelease(shop-floororders,purchaseorders).Documenttheproductionordersassociatedwiththepartsthroughthesystem.Documenttheschedulingsystemanddocumenttrackingofthepartsastheymovethroughthesystem.Documenthowthesystemcommunicateswiththecustomerandsupplier.Documenthowinformationisgathered,i.e.,electronic,manual,““gosee”,etc.38Step6:DrawtheInformationFlowProduction

ControlASSEMBLYSUPPLIERDISTAssemblyAssemblyForgeMachineRawmaterialDailyscheduleForgematerialDailyschedule

Bolts,nuts,washersDailyscheduleO-ring,bearing,snapringDailyschedule

WarehouseReceiving6MonthForecastWeeklyFaxMRP90/60/30DayDailyOrderDailyReleaseCustomer39Production

ControlASSEMBLY20,000pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachineRawmaterialDailyscheduleForgematerialDailyscheduleBolts,nuts,washersDailyscheduleO-ring,bearing,snapringDailyschedule

WarehouseReceiving6MonthForecastWeeklyFaxMRP90/60/30DayDailyOrderDailyReleaseProcess,Material,InformationFlow2/Day1/WeekCustomer40Step6:InformationFlowLiquidPharmaceuticalCurrentStateVSMSupplierRawMaterialsMRPtransactionReceiving0.5111InspectionReceiving1UnpackBottlesUnpack1BottleWasherWasher1Fill&CapFill1HeatShrinkSealer1LabelsonBottlesLabeler1PackProductDropPack1LabelsonPackageLabel1Tag&CratePalletizer1ShrinkWrap&LoadShip1DistributionCenterCustomer888Cases/Day37Cases/Hr11111KitNeckRings2weeksIFDACheckBottleKits16daysIWarehouseIPowder5daysIIISolutionBatchRecordChemicalOrdersOrderSheetProductionPlanningActivatorFinishedGoodsScheduleScheduleFromPlanning(Excel)EmergencyOrdersMRPSystem1ReceivingInspectionLotSample1AnalyticalLabTesting2OffLoad0.5PurifyWaterTankCleanPrepSampleFill&MixReleaseSolutionLabInspectionReceivingLabTestTestGrind1Tumbling1IVials2hrsICaps4hrsBottleWasherWashBottleFillFillBottleCapCapKitting1RingSub-contractorIActivatorBatchRecordIIIIIIIBottleKits16daysIII41Steps5&6DrawtheMaterialandInformationFlowB&DIndustriesExerciseSteps5&6:B&DIndustriesExerciseCompletethefollowingstepsusingtheinformationfromB&DIndustries:CurrentStateMaterialFlowCurrentStateInformationFlowTime:30minutes43Steps5&6DrawtheMaterialandInformationFlowFlygtActivity3HoursStep7ProcessDataCollectionStep7:WhatDataDoYouCollect?Frequency

VariationAssemblyProcessingTimeLeadTimeInventories:RM,WIP,FGDailyVolumeShiftsCostPerUnit:L,O,MVolumeFrequencyVariationCustomerFrequencyTimeDistanceCost46Step7:ProcessDataCollectionCollectProcessDataCycleTimeProcessTimeWIPTaktTimeSet-UpTimeUptimeBatchSize#OperatorsInputsandOutputs(XsandYs)OperatingTime(MinusBreaks)ScrapRateC/T=36SecSetUpTime7MinUptime86%BatchSize50DataBox47Step7:ProcessDataCollectionTips:Usethesametimeunitforcycletimes,takttimes,andavailableworktimes.Avoidtheuseofdecimalminutes.Remembertosubtractbreaks,meetings,andcleanuptimesfromavailableworkingtimepershiftattheprocess.Understandwhattolookforincalculatingbatchsize.Anexamplewouldbeamoldingoperationthatchangesovereveryday.Yourbatchsizewouldbeonedaysworthofparts.Understandthedifferencebetweencycletime,leadtime,andvalueaddtime.48Step7:ProcessDataCollectionProduction

ControlASSEMBLY20,000pcs/moModule=100SUPPLIERDISTAssemblyAssemblyForgeMachineRawmaterialDailyscheduleForgematerialDailyscheduleBolts,nuts,washersDailyscheduleO-ring,bearing,snapringDailyschedule

WarehouseReceiving6MonthForecastWeeklyFaxMRP90/60/30DayDailyOrderDailyRelease2/Day1/WeekCustomerC/T=30SecC/O=30MinUptime95%BatchSize100C/T=45SecC/O=60MinUptime80%BatchSize100C/T=60SecC/O=5MinUptime95%BatchSize100C/T=50SecC/O=10MinUptime95%BatchSize1001000pcs5000pcs100pcs200pcs49Step7:ProcessDataCollectionLiquidPharmaceuticalCurrentStateVSMSupplierRawMaterialsMRPtransactionReceiving0.5111InspectionReceiving1UnpackBottlesUnpack1BottleWasherWasher1Fill&CapFill1HeatShrinkSealer1LabelsonBottlesLabeler1PackProductDropPack1LabelsonPackageLabel1Tag&CratePalletizer1ShrinkWrap&LoadShip1DistributionCenterCustomer888Cases/Day37Cases/Hr11111KitNeckRingsC/T5minutesC/ON/AOEEN/AAvailableTime27,600secondsProcesstime5minutesC/T15minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime15minutesC/T20minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime20minutesC/T0.2minutesC/ON/AOEE98%AvailableTime27,600secondsProcesstime0.2minutesC/T12secondsC/ON/AOEE99%AvailableTime27,600secondsProcesstime12secondsC/T35minutesC/O10minutesOEE97%AvailableTime27,600secondsProcesstime35minutesC/T90minutesC/O180minutesOEE95%AvailableTime27,600secondsProcesstime90minutesC/T45minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime35minutesC/T20minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime20minutesC/T10secondsC/O45minutesOEE96%AvailableTime27,600secondsProcesstime10secondsC/T35secondsC/O30minutesOEE92%AvailableTime27,600secondsProcesstime35secondsC/T120minutesC/O120minutesOEE88%AvailableTime27,600secondsProcesstime2minutesC/T10secondsC/O30minutesOEE98%AvailableTime27,600secondsProcesstime10secondsC/T10secondsC/O30minutesOEE99%AvailableTime27,600secondsProcesstime10secondsC/T30secondsC/O1.5hoursOEE98%AvailableTime27,600secondsProcesstime30secondsC/T10secondsC/O30minutesOEE99%AvailableTime27,600secondsProcesstime10secondsC/T30secondsC/O30minutesOEE98%AvailableTime27,600secondsProcesstime30secondsC/T40minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime40minutesC/T20minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime20minutesC/T20minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime20minutesC/T180minutesC/ON/AOEE98%AvailableTime27,600secondsProcesstime180minutesC/T75minutesC/ON/AOEE98%AvailableTime27,600secondsProcesstime75minutesC/T7secondsC/O30minutesOEE98%AvailableTime27,600secondsProcesstime7secondsC/T2secondsC/O2hoursOEE85%AvailableTime27,600secondsProcesstime2secondsC/T2secondsC/O15minOEE99%AvailableTime27,600secondsProcesstime2secondsC/T25minutesC/O15minOEEXX%AvailableTime27,600secondsProcesstime25minutes2weeksIFDACheckBottleKits16daysIWarehouseIPowder5daysIIISolutionBatchRecordChemicalOrdersOrderSheetProductionPlanningActivatorFinishedGoodsScheduleScheduleFromPlanning(Excel)EmergencyOrdersMRPSystem1ReceivingInspectionLotSample1AnalyticalLabTesting2OffLoad0.5PurifyWaterTankCleanPrepSampleFill&MixReleaseSolutionLabInspectionReceivingLabTestTestGrind1Tumbling1IVials2hrsICaps4hrsBottleWasherWashBottleFillFillBottleCapCapKitting1RingSub-contractorIActivatorBatchRecordIIIIIIIBottleKits16daysIII50Step7ProcessDataCollectionB&DIndustriesExerciseStep7:B&DIndustriesExerciseCreatethefollowingdataboxesforeachprocessstep:CycleTimeChangeovertimeUptimeInventoryAvailableworktimeTime:30minutes52Step7ProcessDataCollectionFlygtActivity4HoursStep8AddProcessandLeadTimeDataStep8:AddProcessandLeadTimeDataDrawatimelineunderprocessboxesandinventorytocompleteproductionleadtimeandprocesstime.16hours1hour2hours1day40hours1hour8hours16hours8hoursProductionLeadTime=91hoursProcessingTime=4hours55SupplierRawMaterialsMRPtransactionReceiving0.5111InspectionReceiving1UnpackBottlesUnpack1BottleWasherWasher1Fill&CapFill1HeatShrinkSealer1LabelsonBottlesLabeler1PackProductDropPack1LabelsonPackageLabel1Tag&CratePalletizer1ShrinkWrap&LoadShip1DistributionCenterCustomer888Cases/Day37Cases/Hr11111KitNeckRingsC/T5minutesC/ON/AOEEN/AAvailableTime27,600secondsProcesstime5minutesC/T15minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime15minutesC/T20minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime20minutesC/T0.2minutesC/ON/AOEE98%AvailableTime27,600secondsProcesstime0.2minutesC/T12secondsC/ON/AOEE99%AvailableTime27,600secondsProcesstime12secondsC/T35minutesC/O10minutesOEE97%AvailableTime27,600secondsProcesstime35minutesC/T90minutesC/O180minutesOEE95%AvailableTime27,600secondsProcesstime90minutesC/T45minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime35minutesC/T20minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime20minutesC/T10secondsC/O45minutesOEE96%AvailableTime27,600secondsProcesstime10secondsC/T35secondsC/O30minutesOEE92%AvailableTime27,600secondsProcesstime35secondsC/T120minutesC/O120minutesOEE88%AvailableTime27,600secondsProcesstime2minutesC/T10secondsC/O30minutesOEE98%AvailableTime27,600secondsProcesstime10secondsC/T10secondsC/O30minutesOEE99%AvailableTime27,600secondsProcesstime10secondsC/T30secondsC/O1.5hoursOEE98%AvailableTime27,600secondsProcesstime30secondsC/T10secondsC/O30minutesOEE99%AvailableTime27,600secondsProcesstime10secondsC/T30secondsC/O30minutesOEE98%AvailableTime27,600secondsProcesstime30secondsC/T40minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime40minutesC/T20minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime20minutesC/T20minutesC/ON/AOEEXX%AvailableTime27,600secondsProcesstime20minutesC/T180minutesC/ON/AOEE98%AvailableTime27,600secondsProcesstime180minutesC/T75minutesC/ON/AOEE98%AvailableTime27,600secondsProcesstime75minutesC/T7secondsC/O30minutesOEE98%AvailableTime27,600secondsProcesstime7secondsC/T2secondsC/O2hoursOEE85%AvailableTime27,600secondsProcesstime2secondsC/T2secondsC/O15minOEE99%AvailableTime27,600secondsProcesstime2secondsC/T25minutesC/O15minOEEXX%AvailableTime27,600secondsProcesstime25minutes2weeksIFDACheckBottleKits16daysIWarehouseIPowder5daysII5days20min16days16days5min5min2weeks20min180min75min7sec2sec2sec25min2secs1weekVA=320.2MinLT=52Days20min10sec35sec2min10sec10sec30sec30sec60sec40minVA=25.6MinLT=64.1Days43days1week30sec5min16daysISolutionBatchRecordChemicalOrdersOrderSheetProductionPlanningActivatorFinishedGoodsScheduleScheduleFromPlanning(Excel)EmergencyOrdersMRPSystem1ReceivingInspectionLotSample1AnalyticalLabTesting2OffLoad0.5PurifyWaterTankCleanPrepSampleFill&MixReleaseSolutionLabInspectionReceivingLabTestTestGrind1Tumbling1IVials2hrsICaps4hrsBottleWasherWashBottleFillFillBottleCapCapKitting1RingSub-contractorIActivatorBatchRecordIIIIIIIBottleKits16daysIII5min2days15min20min12sec35min90min35min4hours4hoursVA=200.2minLT=3.4DaysStep8:AddProcessandLeadTimeDataLiquidPharmaceuticalCurrentStateVSM56Step8AddProcessandLeadTimeDataB&DIndustriesExercise15MinutesStep8AddProcessandLeadTimeDataFlygtActivity45MinutesStep9VerifytheCurrentStateValueStreamMapStep9:VerifytheCurrentStateVSMPeerReviewNon-teammemberswhoknowtheprocess.Reviewprocessbothinternallyand““atitsedges”(theinterfaces).Revisitthelinetoverifycurrentstate.Ensurethatallreworkloopsarecaptured.60IdentifyandPrioritizeImprovementOpportunitiesImprovingtheCurrentStateMakingaValueStreamLeanIdentifyareasofwasteHighlightareasofopportunityLeanprincipleapplicationDetermineFutureStateBreakimplementationintostepsPrioritizeimprovementtoolimplementationValueStreamManagerinvolvement62SevenSourcesofWasteOverproduction(producingtoomuchottoosoon)Waiting(idletime)TransportationUnnecessaryMotionOver-Processing(toomanystepstocompleteajob)InventoryProducingDefects63FutureStateQuestions1.“WhatistheTaktTime?Whatisactualfinalcustomerusage?WhatistheCustomercommunicateddemand?Whatistherange,orvariability?2.““Willyoubuildtoafinishedgoodssupermarket,ordirectlytoshipping?””DoesFinalAssemblybuildandshipdirectlytothecustomer(retail)ortoadistributioncenter?64FutureStateQuestions3.““Wherecanyouusecontinuousflow?””Howcanyouflowwithmaximumvelocity(EPED)withineachplant?4.““Wherewillyouneedtousesupermarketpullsystems?””Doeseach““customer””pullfromitssupplier?5.““Atwhatsinglepointintheproductionchainwillyouscheduleproduction?””Isfinalassemblyinsyncwiththecustomer?65FutureStateQuestions6.““Howwillyouleveltheproductionmix?””Isfinalcustomerdemand(orderingifbuildtoorderorbuyingifbuildtoinventory)level?Does/canthefinalbuildsequencematchactualdemand?Does/canthebuildsequencematchoperations’’capability?7.““Whatincrementofworkwillyouconsistentlyreleaseandtakeaway?””Areyouorcanyouusemilkrunlogistics?66FutureStateQuestions8.““Whatprocessimprovementswillbenecessary?”CaneveryplantinthevaluestreambuildEveryProductEveryDay?Wherecanyoureduceinventorytocutleadtime?1.CutWIPfirst,then2.RawMaterial,then3.FinishedGoodsOverwhelmingmacro-processimprovementneedillustratedbyMacro-Mapping:FixtheInformationsys