Process Mapping/Value Stream Analysis - Indirect Flashcards
What are methods and analysis tools in production and administrative areas?
- In administrative areas one person normally has several parallel roles, the processes are usually not visible.
- In production areas one person usually has just one role. Processes are visible.
To improve performance, what obstacles should be eliminated?
obstacles such as waste, variability and inflexibility must be eliminated
What are examples input streams?
Employees
Process
Materials
Information
What are examples of performance indicators (results)?
Quality
Costs
Service
What are the three obstacles and lean in administration?
Waste
Variability
Inflexibility
What is the obstacle “waste”?
Use of resources going beyond what is necessary to meet customer requirements
What is the obstacle “variability”?
Deviation from standard conditions
What is the obstacle “inflexibility”?
Loss of efficiency due to differences between customer demand and the supply of resources
Which phase of a process do you map the current process and why?
- In the diagnosis phase to get transparency about the process and problems
- To create transparency about waste in the process in the diagnosis phase
What are the 7 steps of process mapping?
- Which process are we talking about? – Process name
- Who are the process participants? – Roles/ function
- What triggers the process? – Initial Input AND How is the process completed? – Output
- What are the individual process steps? – Process box
- What are the process step options for decisions? – Set course
- What obstacles are there? – Kaizen flashes
- How are the process steps linked? – Connecting lines
How to get a value stream map out of a process map?
• Add details like process time, frequency etc.
When value stream mapping, what are some things to keep in mind?
- Use Brownpaper and Sticky notes
- We know that the Post-its will be rearranged several times so use a pencil first before you go with a marker
- Describe the Kaizen flash as detailed as possible, so that a few weeks later you still know what the obstacles were
- Make sure you choose all involved process participants
- Recommendation for group size: 2-5 persons
What are the different synonyms for the current process?
- Actual process or
* AS-IS process
What are the results of value stream mapping?
- Visual representation of process chains and information streams
- Analysis of current situation
- Identification and quantification of kaizen flashes (optimization potential)
- The diagram can be extended to show processing and waiting/queue times as well as the IT systems used
Identifying weaknesses in the value stream requires what?
emphasis on loss factors
What are some of the weaknesses you will find in a VSM?
- Duplicated work
- High stock levels
- Long processing times
- High query quota
- Quality deficits
- Sequential work
- Interfaces
The value stream analysis (VSA) is?
a method of collating the knowledge and experience of the process participants
“Value stream analysis” is a method used to compile the real process
The value stream analysis (VSA) helps what?
- Analyze the complete process chain
- Identify responsibilities for activities and outcomes
- Achieve transparency about the process structure and interfaces
- Estimate process timeframes (milestones, run time based on experience)
- Create transparency about waste in the process
- Find and quantify initial optimization potential and eliminate unnecessary process steps
- Define initial process standards
VSA focuses on what?
collating (combine) the process knowledge of the participants, clarifying the process, and creating transparency
What are the benefits of value stream analysis in indirect areas
Transparency of the real process (talk with the people who perform the process.)
“Go and see” – go and see for yourself how the process is performed on site.
Transparency of complex interactions between different information flows and interfaces (IT, meetings, etc.) on one page.
Compilation of ALL activities (process steps) that result in the process result requested by the customer (value-creating/non-value-creating).
Detailed compilation of times, including query times, transfer times (transport and holding times) and process times (or rework times) and calculation of the processing time.
The process compilation can start from the point of delivery (customer focus).
What are prerequisites of a VSA in an indirect area?
Value stream analysis is useful in areas (departments, teams) with a basic understanding of the process or where there is already an initial process description.
From this basis and using detailed data collection, VSA creates added value.
For areas without a basic understanding of the process or a process description, simple, qualitative process mapping (without recording times) is recommended as an initial optimization measure in the direction of “stabilizing” and “flow.”
When referring to an indirect VSA, what is compilation time?
The time taken to record real process data is as long as the longest process step.
For low frequency or project-related processes, the processing time can be longer than the workshop or project duration.
In this case, alternatives for observation include:
- -Self-recording
- -Process simulation
- -Use of practical knowledge
- -Expert assessment
What are the benefits of value stream analysis in indirect area?
- Transparency of the real process (talk with the people who perform the process.)
- Transparency of complex interactions between different information flows and interfaces (IT, meetings, etc.) on one page.
- Compilation of ALL activities (process steps) that result in the process result requested by the customer (value-creating/non-value creating).
What is the goal of creating target processes?
Goal of creating a target process is to create an efficient process
What is the goal of the ideal state process?
- Efficient process, i.e. exactly what the customer needs will be created (with the minimum of resources).
- All affected employees and managers should be informed before the ideal state process will be implemented.
- For a successful implementation of the ideal state process all measures should be agreed upon by the respective process participants.
What is the ideal state process?
- Eliminate obvious waste, reduce hidden waste
- If possible avoid secession (withdrawal of a group from a larger entity) points/deviations in process map
- Implementation of lean principles
- Direct-line flow of information
- -Few cross functional interfaces
- -One-Piece-Flow
- -Pull-Principle
- -Tact time (if meaningful)
- -Zero-defect target - Short throughput time (simultaneous work, eliminate process steps, combine, accelerate process steps)
With those steps you can create an ideal lean process
Process vision gives you what?
Direction to process optimization
- Create current value stream
- Create a vision in the form of an ideal value flow
- Derivation of a target state using predetermined boundary conditions
- CIP
What are the two most important graphic analysis tools to get yourself and all process participants an overview about the process?
Process Mapping and Value Stream Analysis
