Transforming Your Value Streams Workbook

Transcription

1 Transforming Your Value Streams Workbook Learn how to make value flow one piece at a time. A workbook intended to accompany the Facilitator s Guides for this course. This guide includes the Key Points from the video, discussion items, quiz questions, and helpful tips. Using Gemba Academy s online learning content, any participant can use this workbook to facilitate learning in all courses. July 2017

2 Review What is? Continuous flow is a process that produces one unit at a time and passes it to the next process without delay. It s also called One Piece or Make One Move One. How Do We Make it Happen? Become the Thing : imagine that you are the part in question as you flow through the value stream. Break functional : the value stream manager should try to break through the boundaries between different departments to get them to see the whole value stream. One way to accomplish this is to make sure that representatives of different departments are on the VSM team. Keep it : any time the thing stops or queues up, value is not flowing. This is why excess inventory or WIP is so harmful to flow. Three Types of Flow flow: also called batch and queue, occurs when individual processes are isolated from each other. Inventory is pushed from one process to another without any regard as to whether the next process is ready for more work. flow: workers and workstations are lined up without regard to the cycle time or takt time of each process. Functional boundaries still exist, and work is not balanced. Flow: also called make one move one, each associate produces one piece and passes it to the next process only when that process needs it. One Piece Flow is balanced to takt time, and each operator is aware of what s happening upstream and downstream. Head-to-Head Matchup For this example, we re going to look at 3 processes, each of which takes 1 minute to finish a product. An order comes in for 6 products. 1

3 Batch Flow: Operation 1 produces all 6 units, taking 6 minutes. (6 minutes total) All parts are moved to operation 2, where they wait 2 minutes. ( minutes total) Operation 2 does its work, taking 6 minutes. ( minutes total) All parts are moved to operation 3, where they wait 1 minute. ( minutes total) Operation 3 finishes the products, taking 6 minutes. ( minutes total) Even without the queuing times, 18 minutes are required to finish all 6 products. One Piece Flow: Operation 1 produces one unit, which takes 1 minute. (1 minute total) That unit is passed to operation 2, and operation 1 starts a new one. Both processes take 1 minute. (2 minutes total) Operation 3 processes the first unit, the second unit goes to operation 2, and operation 1 starts on a new product. (3 minutes total) In essence, we are not able to produce the first product after 3 minutes, and an additional product every minute after. All of the products are finished after minutes. While One Piece Flow s reduction of lead time is a huge benefit, it has other advantages as well, such as the better utilization of assets, lower chances of overproduction, and the increased chance of spotting defects sooner. Cellular Layout Once an organization commits to one piece flow, they should look at the way they design and lay out production lines. In batch layouts, each department is separated by, and are more focused on completing the job at a departmental level rather than a cross-departmental level. The flow streams are also erratic and tangled In one piece flow layouts, value streams are streamlined into U-shaped, and by cross-training and dedicating more people to the process, lead-time is reduced dramatically. Make sure you design the workstation around the needs of the process while ensuring that they have and checkpoints. This kind of cell layout is best suited for the repetitive workflow of smaller, lighter 2

4 components. Prerequisites for One Piece Flow A and controlled process: if your defect rate is 50%, focus on your quality problems first. : you need to have the courage to stop the line whenever you have a problem, to challenge your problems when they appear, and to be uncomfortable when starting one piece flow. 3

5 Quiz 1. Please number the three steps to making value flow into the correct order. Break through functional boundaries Keep the thing moving Become the thing (imagine you are the actual part) 2. What kind of flow is being depicted in the image below? one piece flow fake flow batch flow 3. What type of flow is being depicted in the image below? batch flow one piece flow fake flow 4. What type of flow is being depicted in the image below? batch flow fake flow one piece flow 5. A U-shaped cell layout is extremely well suited for repetitive workflow of smaller, lighter components. True False 4

6 Reflection How will you and your value stream mapping effort benefit from continuous flow? 5