Creating Mixed Model Value Streams
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Creating Mixed Model Value Streams
Following in the footsteps of its bestselling predecessor, Kevin J. Duggan, an executive mentor and recognized authority on Lean and Operational Excellence, draws on more than 10 years of experience and learning to provide Creating Mixed Model Value Streams, Second Edition. This second edition takes a step-by-step approach to implementing Lean in complex environments and describes which Lean techniques to use when faced with difficult situations—including high product mix, scheduling problems, shared resources, and unstable customer demand. In addition to a new section on handling shared resources to support mixed model production, the second edition: Contains updates to sections on mixed model value streams Introduces new information on constructing product family matrices Expands on the concept of takt in mixed models Provides additional insights on existing mixed model concepts, such as determining product family, takt capability, and heijunka (load level scheduling) Presents new concepts on sequencing work, such as offset scheduling and sequenced first-in, first-out (FIFO) lanes Illustrated with a case study based on actual experience as well as downloadable resources with helpful tools, the book walks readers through the reasoning the author has used with great success in practice. It delves beyond the basics of value stream mapping to explain how to create future states in a manufacturing environment characterized by multiple products, varying cycle times, and changing demand. Demonstrating advanced techniques for creating flow through shared resources, it also considers the concept of a guaranteed turnaround time for the shared resource. The Downloadable Resources Include: Spreadsheet and tutorial for sorting products into families Spreadsheets for calculating equipment required and for determining the interval for Every Part Every Interval (EPEI) Samples of visual method sheets for standard work Case study value stream maps and mapping icons
Leveraging Digital Mixed Model Value Stream Maps
This guide serves as a roadmap for integrating digital value stream mapping (eVSM) into your Lean deployment to improve production processes. Lean, with its mapping component, value stream mapping (VSM), has endured as a process improvement methodology for more than 25 years. VSM is a metrics-based analytical mapping method with simple calculations for Lean metrics such as Takt Time, VA, NVA, Capacity, OEE, etc., however: • The calculations and charting associated with value stream maps can be tedious. • It’s hard to keep updating the calculations for “what-if” studies. • Manual calculations can be prone to error. Digital VSM was introduced as a complement to the initial paper-and-pencil map. The eVSM software has been used to create Digital VSMs for many years, but it has also encountered a couple of hurdles: • Lean application has expanded and is applied to increasingly complex value streams. • Product variants (mixed models) have proliferated so that many variants are now made with shared resources. Creating and analyzing mixed model value stream maps with only paper and pencil, however, is practically unfeasible. The eVSM program has been revamped for the mixed model production setting and is now accessible as eVSM Mix for creating and analyzing Digital Mix VSMs. The eVSM Mix software reintroduces VSM as a fundamental tool for lean practitioners working in mixed-model situations. This guide illustrates Digital Mix VSMs created with the eVSM Mix software, shows how to use them analytically for “what-if” studies, and highlights best practices for deployment.
Learning to See
Lean production is the gold standard in production systems, but has proven famously difficult to implement in North America. Mass production relies on large inventories, uses "push" processes and struggles with long lead times. Moving towards a system that eliminates muda ("waste") caused by overproduction, while challenging, proves necessary for improved efficiency. Often overlooked, value stream mapping is the essential planning stage for any Lean transformation. In Mike Rother and John Shook's essential guide, you follow the value stream mapping undertaken for Acme Stamping, for its current and future state. Fully illustrated and well-organized, Learning to See is a must-see for the value stream manager.