ADVANCED MANUFACTURING SYSTEMS VALUE STREAM MAPPING 11012022 Advanced

ADVANCED MANUFACTURING SYSTEMS

VALUE STREAM MAPPING 11/01/2022 Advanced Manufacturing Systems 2

VALUE STREAM MAPPING • Special type of flow chart that uses symbols known as "the language of Lean" to depict and improve the flow of inventory and information • A way to keep track of goods and materials as they move through the product creation process that helps a business boost productivity and reduces waste • A typical value stream mapping process will begin with the delivery of raw materials, proceed through intermediate states of production, and then conclude with the creation of a finished product ready for sale to consumers. 11/01/2022 Advanced Manufacturing Systems 3

VALUE STREAM MAPPING • VSM ditemukan oleh John Shook dan Mike Rother dalam mendokumentasikan aliran material dan informasi dari suatu sistem manufaktur (1998) • VSM adalah suatu teknik/alat dari lean berupa gambar yang digunakan untuk menganalisa aliran dari material dan informasi yang disiapkan untuk membawa barang dan jasa kepada customer • TOYOTA – Material and Information Flow Mapping 11/01/2022 Advanced Manufacturing Systems 4

VALUE STREAM MAPPING PURPOSE • Provide optimum value to the customer through a complete value creation process with minimum waste in: • Design (concept to customer) • Build (order to delivery) • Sustain (in-use through life cycle to service) 11/01/2022 Advanced Manufacturing Systems 5

8 WASTE • • Defect Scrap Over production Inventory Transportation Motion Waiting/delays (man power, material, machine) Processing time 11/01/2022 Advanced Manufacturing Systems 6

WHY? • Many organizations pursuing “lean” conversions have realized that improvement events alone are not enough • Improvement events create localized improvements, value stream mapping & analysis strengthens the gains by providing vision and plans that connect all improvement activities • Value stream mapping & analysis is a tool that allows you to see waste, and plan to eliminate it 11/01/2022 Advanced Manufacturing Systems 7

KELEBIHAN • Dapat menghubungkan langkah-langkah dalam proses manufaktur kepada komponen lainnya seperti komponen supply chain (distribusi, supplier, dan pengendalian produksi) • Mengintegrasikan material dan aliran informasi dalam proses manufakturing • Menghubungkan fungsi Production Control dan Scheduling kepada pekerja lapangan • Mengintegrasikan teknik industri yang lain untuk material dan analisa aliran informasi 11/01/2022 Advanced Manufacturing Systems 8

KEKURANGAN • Gagal untuk memetakan berbagai produk yang tidak mempunyai rute yang serupa • Gagal untuk menghubungkan tata letak pabrik dan/atau material handling untuk proses dan parameter peralatan • Kekurangmampuan dalam ukuran ekonomi untuk “value” • Ketidakmampuan dalam menata ruang fasilitas di pabrik • Biasanya hanya untuk produk yang tinggi volumenya tapi varietasnya rendah • Gagal untuk menurunkan nilai waktu tentang keterlambatan aliran dalam setup, proses, antrian setiap proses, material handling, dll. serta keterlambatan dalam pengadaan kapasitas dan order dalam setiap proses 11/01/2022 Advanced Manufacturing Systems 9

WHAT IS VALUE? • A capability provided to a customer • of the highest quality, • at the right time, • at an appropriate price, as defined by the customer. • "Value" is what the customer is buying 11/01/2022 Advanced Manufacturing Systems 10

WHAT IS VALUE STREAM? • All of the activities, required to fulfil a customer request from order to delivery (and beyond to cash received) 11/01/2022 Advanced Manufacturing Systems 11

WHAT IS VALUE STREAM ANALYSIS? • Planning tool to optimize results of eliminating waste 11/01/2022 Advanced Manufacturing Systems 12

VSM STEPS 11/01/2022 Advanced Manufacturing Systems 13

APPLY FIVE SIMPLE PRINCIPLES • Specify value from the standpoint of end customer • Identify the value stream for each product family • Make the product flow • So the customer can pull • As you manage toward perfection 11/01/2022 Advanced Manufacturing Systems 14

WHAT IS THE VALUE THAT FLOWS? • Specify value from the standpoint of the end customer • Ask how your current products and processes disappoint your customer’s value expectation: • • • price? quality? reliable delivery? rapid response to changing needs? ? 11/01/2022 Advanced Manufacturing Systems 15

WHAT FLOWS? • "ITEMS" flow through a value stream • In manufacturing, materials are the items • In design & development, designs are the items • In admin. , internal customer needs are the items • Analysis begins with part of a total value stream, That part of the value stream has customers too 11/01/2022 Advanced Manufacturing Systems 16

TOTAL VALUE STREAM INTERNAL PLANT 11/01/2022 Advanced Manufacturing Systems 17

IMPLEMENTASI VSM • Identifikasi value stream dari proses, untuk dikembangkan diatur batasannya • Identifikasi pelayanan terhadap konsumen dengan menggunakan value stream dan catatan apa yang mereka ingin dan butuhkan customer value • Petakan value stream tersebut • • Petakan setiap proses dan pesanannya Berikan waktu untuk setiap operasi (processing time) Tentukan waktu tunggu untuk setiap operasi (waiting time) Jumlah dan hitung work in process • Pelajari value stream dan temukan waktu menganggur dan WIP terbesar • Analisa peta tersebut dengan mencari pemborosan (waste) terkecil dan berapa lama produk dapat dihasilkan dengan waktu yang sedikit • Implementasikan hasil di dalam pabrik • Tingkatkan ide untuk menyelesaikan permasalahan yang ada • Ukur peningkatan yang telah dibuat • Standarkan proses operasi yang baru 11/01/2022 Advanced Manufacturing Systems 18

CURRENT VSM • • • • Draw customer, supplier and production control icons Enter customer requirement per month and per day Calculate daily production and container requirement Draw outbound shipping icon and truck with delivery frequency Draw inbound shipping icon, truck and delivery frequency Add process boxes in sequence, left to right Add data boxes Add communication arrows and note methods and frequencies Obtain process attributes and add to data boxes; observe all times directly Add operator symbols and numbers Add inventory locations and levels in days of demand graph at bottom Add push, pull and FIFO icons Add other information that may prove useful Add working hours Cycle and lead times Calculate total cycle time and lead time 11/01/2022 Advanced Manufacturing Systems 19

FUTURE VSM • • Calculate takt time Identify bottleneck process Identify lot sizing/set up opportunities Identify potential workcells Determine kanban locations Establish scheduling methods Calculate lead and cycle time 11/01/2022 Advanced Manufacturing Systems 20

VALUE STREAM MAPPING PROCESS SYMBOLS 11/01/2022 Advanced Manufacturing Systems 21

VALUE STREAM MAPPING MATERIAL SYMBOLS 11/01/2022 Advanced Manufacturing Systems 22

VALUE STREAM MAPPING MATERIAL SYMBOLS 11/01/2022 Advanced Manufacturing Systems 23

VALUE STREAM MAPPING INFORMATION SYMBOLS 11/01/2022 Advanced Manufacturing Systems 24

VALUE STREAM MAPPING INFORMATION SYMBOLS 11/01/2022 Advanced Manufacturing Systems 25

VALUE STREAM MAPPING INFORMATION SYMBOLS 11/01/2022 Advanced Manufacturing Systems 26

VALUE STREAM MAPPING GENERAL SYMBOLS 11/01/2022 Advanced Manufacturing Systems 27

TAKT TIME • Takt Time is "Beat Time"? "Rate Time" or “Heart Beat" Lean Production uses Takt Time as the rate or time that a completed product is finished. If you have a Takt Time of two minutes that means every two minutes a complete product, assembly or machine is produced off the line. (http: //www. isixsigma. com/dictionary/Takt_Time-455. htm) 11/01/2022 Advanced Manufacturing Systems 28

CURRENT STATE - MANUFACTURING 11/01/2022 Advanced Manufacturing Systems 29

IDEAL STATE - MANUFACTURING 11/01/2022 Advanced Manufacturing Systems 30

FUTURE STATE - MANUFACTURING 11/01/2022 Advanced Manufacturing Systems 31

IDEAL STATE – NON MANUFACTURING 11/01/2022 Advanced Manufacturing Systems 32

FUTURE STATE - NON MANUFACTURING 11/01/2022 Advanced Manufacturing Systems 33

EXAMPLE • John Smith works for ABC Company in charge of production. ABC company makes widgets and supply these through several retail outlets. Recently problems have emerged. • a shortage in supply to the retail outlets • Has high levels and value of inventory in the organization currently • a complaint letter to the company from a customer stating that as a frequent consumer of the products, he’s dissatisfied at the quality of the product and that he often returns faulty widgets to the retail outlets • John’s unsure how to answer to these questions but he intends to get to the bottom of it and if possible improve the situation. 11/01/2022 Advanced Manufacturing Systems 34

GUIDE • Step 1 - Select your sponsor and set expectations • appoint someone who is responsible to make decisions, arbitrate solutions, and plan the project. • The sponsor usually selects the processes that will be mapped and will usually have a firm grasp of what achievement is being targeted. • Step 2 - Select your team • You should ensure that each area or stakeholder of the process is represented e. g. Sales, Purchasing, Warehouse etc. • Step 3 -Select process to be mapped • Value Stream Mapping is suitable for most businesses and can be used in Manufacturing, Logistics, Supply Chain and some Service orientated Organizations. 11/01/2022 Advanced Manufacturing Systems 35

GUIDE • Step 4 - Collect data and produce current state map • process times, inventory or materials information, customer (or demand) requirements. • the future state maps will be developed using information captured here so it’s imperative you have a correct understanding of the business. • Step 5 - Critique Current state • challenge the current thinking, encourage your team to make suggestions, look for areas of waste. • Step 6 - Map Future State • compile a future state map based on the current state map and the critiques 11/01/2022 Advanced Manufacturing Systems 36

GUIDE • Step 7 - Create Action Plan and deploy • taking the Future State map consider an action plan that could be implemented to change the current process to the future state. • Step 8 - Measure benefits • check to ensure that the benefits expected have been obtained – review each change made and analyze benefits 11/01/2022 Advanced Manufacturing Systems 37

MAPPING TIPS • Always collect current-state information while walking the actual pathways of material and information flows yourself • Begin with a quick walk along the entire door-to-door value stream • Begin at the shipping end and work upstream • Bring your stopwatch and do not rely on standard times or information that you do not personally obtain • Map the whole value stream yourself • Always draw by hand in pencil 11/01/2022 Advanced Manufacturing Systems 38

TOOLS • • Process activity mapping Supply chain response matrix Production variety funnel Quality filter mapping Demand amplification mapping Decision point analysis Physical structure mapping 11/01/2022 Advanced Manufacturing Systems 39

PROCESS ACTIVITY MAPPING • Memetakan keseluruhan aktivitas secara detail guna mengestimasi waste, ketidakkonsistenan, dan kerasionalan di tempat kerja sehingga tujuan meningkatkan kualitas produk dan memudahkan layanan, mempercepat proses, dan mereduksi biaya diharapkan dapat terwujud • Process Activity Mapping akan memberikan gambaran • • Aliran fisik dan informasi Waktu yang diperlukan untuk setiap aktivitas Jarak yang ditempuh Tingkat persediaan produk dalam setiap tahap produksi • Kemudahan identifikasi aktivitas terjadi karena adanya penggolongan aktivitas menjadi 5 jenis • • • Operasi Transportasi Inspeksi Delay Penyimpanan 11/01/2022 Advanced Manufacturing Systems 40

PROCESS ACTIVITY MAPPING • Langkah • Dilakukan analisa awal untuk setiap proses yang ada • Mengidentifikasi waste yang ada • Mempertimbangkan proses yang dapat diubah agar urutan proses bisa lebih efisien • Mempertimbangkan pola aliran yang lebih baik • Mempertimbangkan segala sesuatu untuk setiap aliran proses yang benar-benar penting saja 11/01/2022 Advanced Manufacturing Systems 41

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SUPPLY CHAIN RESPONSE MATRIX • Memberikan gambaran kondisi lead time untuk setiap proses dan jumlah persediaan sehingga pemantauan terjadinya peningkatan atau penurunan lead time dan jumlah persediaan di setiap area aliran rantai pasok dapat dilakukan • Memudahkan manajer distribusi untuk mengetahui pada area mana distribusi dapat direduksi leadtimenya dan dikurangi jumlah persediaannya 11/01/2022 Advanced Manufacturing Systems 43

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PRODUCTION VARIETY FUNNEL • Untuk mengetahui pada area mana terjadi bottleneck dari aliran masukan bahan baku, proses produksi, sampai pengiriman kepada konsumen • Karakteristik yang berhasil dirumuskan karena adanya perbedaan proses produksi di industri • Pabrik yang produksinya cenderung tidak berubah – industri kimia • Pabrik yang jumlah bahan bakunya terbatas akan tetapi variasi produknya banyak – industri tekstil dan metal • Pabrik yang jumlah bahan bakunya banyak akan tetapi produk jadinya relatif terbatas – industri pesanan • Pabrik yang produk jadinya relatif beragam dan jumlah komponen yang terbatas – industri elektronik, rumah tangga 11/01/2022 Advanced Manufacturing Systems 45

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QUALITY FILTER MAPPING • Alat baru yang didesain untuk mengidentifikasikan masalah kualitas pada area aliran rantai pasok perusahaan • Defect dari kualitas • Product defect cacat fisik produk yang tidak berhasil diseleksi pada saat proses inspeksi sehingga lolos ke konsumen • Scrap defect cacat yang berhasil diseleksi pada saat proses inspeksi • Service defect masalah yang ditemukan oleh konsumen pada saat pemakaian produk, akan tetapi tidak secara langsung berhubungan dengan produk yang dihasilkan tetapi lebih kepada pelayanan yang diberikan dari perusahan • Waktu pengiriman yang tidak tepat waktu • Saat setup/pengukuran produk yang akan digunakan 11/01/2022 Advanced Manufacturing Systems 47

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DEMAND AMPLIFICATION MAPPING • Alat yang dapat digunakan sebagai dasar pengambilan keputusan dan analisis ke depan untuk mendesain konfigurasi aliran nilai, mengatur fluktuasi permintaan sehingga permintaan yang ada dapat dikendalikan 11/01/2022 Advanced Manufacturing Systems 49

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DECISION POINT ANALYSIS • Sering digunakan pada pabrik yang berkarakteristik produk jadinya relative beragam dan jumlah komponen yang terbatas • Industri elektronik • Industri rumah tangga • Titik keputusan adalah titik dimana tarikan permintaan aktual memberikan cara untuk mendorong adanya peramalan • Informasi titik ini berguna untuk mengetahui terjadinya kekeliruan penentuan titik keputusan • Untuk jangka pendek, informasi yang ada memungkinkan memprediksi proses yang beroperasi baik dari hilir maupun hulu dari titik keputusan • Untuk jangka panjang, informasi yang ada digunakan untuk mendesain skenario untuk memperlihatkan operasi dari aliran nilai jika titik keputusan tersebut berubah; harapannya, akan memberikan desain skenario yang lebih baik dibanding sebelumnya 11/01/2022 Advanced Manufacturing Systems 51

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PHYSICAL STRUCTURE • Struktur volume menunjukkan struktur industrinya antara area pemasok dan distribusi dengan variasi yang bertingkat • Diagram pemetaan menggambarkan biaya yang dikeluarkan perusahaan dari biaya bahan baku sampai dengan perakitan • Memiliki hubungan langsung dengan proses-proses yang terjadi di perusahaan yang berkarakteristik value-adding • Berguna untuk mengetahui fakta apa yang terjadi pada aliran rantai pasok secara keseluruhan dan mengetahui level dari industrinya 11/01/2022 Advanced Manufacturing Systems 53

END OF THIS CHAPTER 11/01/2022 Advanced Manufacturing Systems 54