Value Stream Mapping

Question 1

What is value?

Answer 1

how the specific product or service meets the customer’s needs, at a specific price, at a specific time

Question 2

An activity is value-added if:

Answer 2

• it directly transforms the product or service closer to what the customer wants
• it is done right the first time
• the customer wants it and is willing to pay for it

Question 3

What is a value steam?

Answer 3

the entire sequence of activities in a system required to produce a product or service

Question 4

What are the 3 main components of a value stream?

Answer 4

1) flow of materials from the supplier to the customer
2) transformation of raw materials into finished goods or services
3) the flow of information is used to support the flow of materials and transformation

Question 5

What are the 3 types of activities in a value stream?

Answer 5

value-added

non-value-added - necessary to stay in business such as paying taxes

pure waste

Question 6

What is value stream mapping?

Answer 6

a lean tool that helps an organization understand the flow of materials and information through the value stream

Question 7

A value stream map is a ___________ map with _____________.

Answer 7

process, metrics

Question 8

What are typical VSM metrics?

Answer 8

• cycle time of an operation (C/T)
• machine or systems uptime
• changeover time (C/O)
• overall equipment effectiveness (OEE)
• number of operators
• value-added time of an operation
• wait time
• scrap rate
• lead time
• percent complete and accurate

Question 9

The current state must reflect _________, not the way the process was ___________ or the way the documentation states.

Answer 9

reality, designed

Question 10

______________________ the current state map by walking the process to ensure no steps were missed.

Answer 10

Validate

Question 11

How do you use VSM?

Answer 11

• current state VSM
• desired future state VSM
• welcome diversions when they come up

Question 12

What is cycle time?

Answer 12

the time it takes for a process to run from start to finish

Question 13

What are two ways to reduce cycle time?

Answer 13

• strive for continuous flow
• reduce time spent on changing from one product or service to the next

Question 14

What are tools for reducing cycle time? (7)

Answer 14

1) workflow analysis
2) value stream analysis
3) process design
4) countermeasure activities
5) six sigma projects
6) cycle time adjustments
7) standard work

Question 15

What is cellularization?

Answer 15

analyzing the current process and determining if there are bottlenecks causing parts or materials to back up

Question 16

How is continuous flow used to reduce cycle time?

Answer 16

1) as materials flow, value is added
2) new flow is created which requires a new layout
3) value adding steps are arranged one after another for no piles between steps
4) moving away from batch processing

Question 17

What is set up reduction/changeover reduction/Single Minute Exchange of Die (SMED)?

Answer 17

a tool to speed up the time in a process

Question 18

What are the steps of set up reduction? (10)

Answer 18

1) video is taken of set process
2) set up time is measured
3) detailed elemental analysis
4) elements assessed as internal or external (internal = process stopped, external = still producing)
5) move internal elements to external elements
6) optimize remaining tasks
7) new process is tried and measured
8) feedback gathered and adjustments made
9) new process is rolled out
10) review process to make sure it is sustained