Map the Value Chain

• Current State Map
  • Map the material and information flow in the Model Area.
• Future State Map
  • Develop a map for the Model Area with continuous flow, pull systems and waste eliminated.
• Set goals for the implementation project
• Develop an implementation plan
• Steering committee
  • Review the goals: Current State and Future State Maps, and the implementation plan with the steering committee.
  • Obtain the steering commitee’s approval to proceed.

Model Area Implementation Approach

• Stability

• Equipment reliability
• Process capability

• Continuous flow
• Synchronized production
• Pull system
• Level production

Current State Map of the Model Area

1. Collect current state information while walking the actual material and information flows.
2. Begin with a quick walk along the entire Model Area value stream to get a sense of the flow and sequence of processes.
3. Start at shipping for material flow and work upstream. Start at order entry for information flow.

Develop the Future State Map

• Determine Takt Time.
• Use continuous flow processing.
• Select the pacemaker production process.
• Will we need to introduce supermarket pull systems in order to control production of upstream processes?
• Will we build a finished goods supermarket from which the customer pulls, or build directly to customer order?
• How will we level the production mix at the pacemaker process?
• What process improvements will be necessary for the value stream to flow as the Future State design specifies?

Set Goals

• From the gap between the Current State Map and Future State Map, estimate savings and set goals for the Lean Manufacturing implementation project.
  • Lead time reduction
  • Inventory reduction
  • Productivity improvement
  • Floor space savings
  • Quality improvement

Implementation Plan

• From the gap between the current State Map and Future State Map, develop a Lean Manufacturing implementation plan.

Steering Committee

• Review the goals, Current State and Future State Maps, and the implementation plan with the steering committee.
• Obtain the steering committees approval to proceed.