Mapping the Total Value Stream: A Comprehensive Guide for Production and Transactional Processes

296 Pages·2008·10.28 MB·English

by  Mark Nash and Sheila R. Poling

MAPPING THE TOTAL
VALUE STREAM
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MAPPING THE TOTAL
VALUE STREAM
A Comprehensive Guide for
Production and Transactional Processes
MARK A. NASH AND SHEILA R. POLING
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Productivity Press
Taylor & Francis Group
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© 2008 by Taylor & Francis Group, LLC
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Library of Congress Cataloging-in-Publication Data
Nash, Mark A., 1959-
Mapping the total value stream : a comprehensive guide for production and transactional processes / Mark A. Nash and Sheila R.
Poling.
p. cm.
Includes bibliographical references and index.
ISBN 978-1-56327-359-9 (alk. paper)
1. Production engineering. 2. Production management. 3. Process control. I. Poling, Sheila R. II. Title.
TS176.N365 2008
658.5--dc22 2007048326
Visit the Taylor & Francis Web site at
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and the Productivity Press Web site at
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Dedication
This book is dedicated to the three most important women in my
life—Staci, Ally, and Delaney—who continually put up with my
time alone to work on projects like this. And a special thank you
to Roxie Craycraft who years ago reminded me of the importance
of documenting the current state before looking at the future.
Mark A. Nash
I would like to dedicate this book to all of the people I have worked with in
the past, those I work with in the present, and those with whom I will work in
the future. By collaborating with a variety of industry experts, I have been able
to learn, share, and develop new concepts beyond any I would have created as
an individual contributor. This is what continual improvement is truly about.
My involvement in this book is a direct result of my friendship with a
person I consider to be a Lean Master—Mark Nash. I cannot express the
pleasure I have had working on this and other projects with him. Due to
our professional alliance, I have learned more about Lean and been given a
new perspective and additional insights on quality improvement in general.
I hope our successful partnership continues for many years to come.
Sheila R. Poling
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Contents
Acknowledgments .................................................................................xiii
Introduction ........................................................................................... xv
About the Authors ................................................................................. xix
1 The Big Picture … Literally
Understanding the Purpose and Power of Value Stream Mapping ......1
Introduction ........................................................................................................ 1
Dissecting a Basic Value Stream Map ............................................................... 2
The Process or Production Flow in a Value Stream Map ......................... 2
The Communication or Information Flow in a Value Stream Map .......... 6
The Timelines and Travel Distances Shown in a Value Stream Map ....... 6
Understanding the Icons Used in Value Stream Mapping ................................ 9
Production versus Transactional Mapping: Understanding the Similarities
and Differences .................................................................................................. 9
SECTION I: CurrENT STaTE: uNDErSTaNDINg aND MappINg YOur
ExISTINg prOCESS
2 Identifying the Value Stream ............................................................17
Introduction .......................................................................................................17
Option 1: The Matrix Approach ...................................................................... 18
Production Process Matrix ....................................................................... 18
Transactional Process Matrix ................................................................... 21
Option 2: Ready, Aim, Map—Production and Transactional
Value Streams ................................................................................................... 25
3 Collecting Basic Information about the Current State..................... 29
Introduction ...................................................................................................... 29
Capturing Basic Information ............................................................................ 29
Begin to Map Your Process ..................................................................... 30
Calculating Takt Time ...................................................................................... 34
4 Documenting Manufacturing (or Production) Process Flow ........... 39
Introduction ...................................................................................................... 39
Identifying and Mapping the Main Flow ........................................................ 40
Map How the Product Moves from One Step to the Next ..................... 42
vii
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viii n Contents
Map Where the Inventory Is .................................................................... 43
Map Where the Operators Are Located .................................................. 44
Putting It All Together .............................................................................. 44
Mapping Subtasks and Parallel Flows ............................................................. 45
Mapping Subtasks ..................................................................................... 45
Mapping Parallel or Alternate Paths ........................................................ 46
Lining Up Process Steps .................................................................................. 47
Aligning the Process Horizontally ........................................................... 48
Aligning the Process Vertically ................................................................ 49
The Power of Speed ........................................................................................ 50
5 Documenting Transactional Process Flow ....................................... 51
Introduction .......................................................................................................51
“The Product” in a Transactional World ......................................................... 52
Choosing the Level to Map .............................................................................. 52
Understand the Focus of the Value Stream..................................................... 52
Start with the Workfow ................................................................................... 53
Mapping Subtasks and Parallel Tasks .............................................................. 55
6 Showing the Flow Clearly ................................................................ 57
Introduction ...................................................................................................... 57
Providing Defnition to Subtasks and Parallel Paths ....................................... 57
Mapping the Reality of Rework ....................................................................... 58
Using Terminators to Clarify Rework in the Flow .......................................... 59
The Power of Simplicity ................................................................................... 62
7 Interpreting and Understanding Basic Product Flow...................... 65
Introduction ...................................................................................................... 65
Showing Where Flow Starts and Ends ............................................................ 65
The Traditional Mindset: Pushing Work.......................................................... 66
The Lean Concept of Pull Systems .................................................................. 66
Controlling Material When Pull Is Not Possible.............................................. 68
Calculating Customer Demand and Takt Time ............................................... 69
Showing Inventory ........................................................................................... 71
Capturing Cycle Time .......................................................................................74
Summarizing Basic Process Flow .................................................................... 76
Case Study in a Manufacturing Environment ................................................. 77
8 Utilizing Data in Manufacturing
How to Add Power to Your Map with Facts ................................................79
Introduction ...................................................................................................... 79
Record the Number of Operators for Each Process ........................................ 80
Record the Cycle Time of Each Process Step ................................................. 81
Record the Changeover Time from One Process to Another ......................... 82
Record Uptime, or the Reliability of Equipment ............................................. 83
Record the Availability of Equipment .............................................................. 85
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Contents n ix
Record Work Content and Non-Value-Added Time ........................................ 87
Record the Defect Rate .................................................................................... 87
Other Data You Might Want to Record on Your Map .................................... 89
9 Basic Process Flow in a Transactional World .................................. 91
Transactional versus Manufacturing Process Flow ......................................... 91
Difference 1: Speed of Transactional Processes.............................................. 92
Option A: Map the Process by Using the Employees’
Knowledge of the Process ....................................................................... 92
Option B: Map the Process by Working Backwards
from the Last Process Step ....................................................................... 93
Option C: Use Both Options A and B ..................................................... 93
Difference 2: Transactional Employees Sometimes Do Not See
a Process........................................................................................................... 93
Difference 3: Takt Time in Transactional Value Streams ................................ 94
Difference 4: Work Queues versus Piles of Inventory .................................... 95
10 Transactional Data Is Different … Or Is It? .................................... 97
Introduction ...................................................................................................... 97
Recording the Number of Employees in a Transactional Setting ................... 98
Documenting Cycle Time ................................................................................ 98
Documenting Expected (Estimated) Cycle Time .................................. 100
Documenting Changeover Time.................................................................... 100
Documenting Uptime or Reliability ...............................................................101
Documenting Availability of Equipment (AOE) .............................................102
Documenting Availability of Personnel (AOP) ...............................................103
How to Document Tasks That Supervisors and Managers
Demand Be Performed Immediately ......................................................105
Documenting Defects .....................................................................................107
Capturing Other Data .....................................................................................107
Case Study in a Transactional Environment ..................................................110
11 Capturing Travel Distances throughout the Value Stream .............111
Introduction .....................................................................................................111
Measuring Travel Distance in the Value Stream ............................................111
Measuring and Documenting the Travel Path of the Product ...............112
Measuring and Documenting the Travel Path of Employees ................113
Physical Measurement of Travel ..............................................................114
Showing Travel Distance on a Value Stream Map .........................................115
Documenting Long Travel Distances within a Process Step .........................116
Check for Hidden Travel in Transactional Processes .....................................117
12 Showing the “Value” from the Process Flow ................................. 121
Introduction .....................................................................................................121
Measuring Total Cycle Time ...........................................................................122
Interpreting Parallel or Subtask Cycle Times .........................................124
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