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Value Stream Mapping: Submitted By-Aanchal Chawla (DFT-VI)

Value stream mapping (VSM) is a tool used in lean management to map and analyze the flow of materials and information as a product moves through the manufacturing process. It identifies value-adding and non-value adding activities in order to eliminate waste. VSM involves creating current and future state maps to visualize process flows and identify opportunities for improvement, such as reducing lead times and synchronizing processes. Implementing VSM successfully can help garment manufacturers address common problems like excess work-in-process, delays, and capacity constraints. While VSM provides benefits, its implementation must be gradual to avoid instability as the value stream is optimized in stages.

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248 views9 pages

Value Stream Mapping: Submitted By-Aanchal Chawla (DFT-VI)

Value stream mapping (VSM) is a tool used in lean management to map and analyze the flow of materials and information as a product moves through the manufacturing process. It identifies value-adding and non-value adding activities in order to eliminate waste. VSM involves creating current and future state maps to visualize process flows and identify opportunities for improvement, such as reducing lead times and synchronizing processes. Implementing VSM successfully can help garment manufacturers address common problems like excess work-in-process, delays, and capacity constraints. While VSM provides benefits, its implementation must be gradual to avoid instability as the value stream is optimized in stages.

Uploaded by

Aanchal Chawla
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPTX, PDF, TXT or read online on Scribd
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Value Stream Mapping

Submitted By- Aanchal Chawla(DFT-VI)


What is Value Stream Mapping (VSM)?

Value Stream Mapping (VSM), is a tool used for lean


management, which can be used for any value chain i.e.
the process of activities in the manufacturing process that
are adding value to the product being made.

Also known as material and information flow analysis


diagram, it maps the path of production and identifies key
waste elimination opportunities.
Image Reference- Article on Value Stream Mapping and WIP reduction – A potent tool for ‘operational excellence’ in apparel
industry By Mr. Anand Deshpande on apparelresources.com
Problems faced by the garment
manufacturing shop floor
• Many pieces waiting to be reworked
• Larger lots causing a huge amount of delay
• No standard WIP being maintained on the floor
• Stocks getting misplaced in stores and shop floor
• Overproduction
• High replenishment time experienced in raw material and
finished goods stores
• High turnaround time
• Poor first time through per cent (FTT%)
• Process delays due to lack of synchronization between
preparatory sections
• Capacity constraints induced by skill variability and individual
variability
• Longer set-up times between product changeovers and
challenges of multi-skilling.
How VSM can be helpful for such
problems?

Material and information flow diagram can be used to identify


non-value added activity for which the customer is not paying for,
by
• making current and desired future state map and
• making the necessary changes as a team and implementing them
to remove ‘mudas’, so as to have a smooth flow of material from
each department and reducing waste.
• If successfully implemented, the cycle time for each process will
be reduced, thus compressing the lead time
Steps to implement VSM

Product family is
identified

The current state map


is drawn

The desired future


state mapping is done

Project is planned to
eliminate waste.
Limitation of VSM Approach
• As the changes are implemented in the initial stage, each
operation in the value stream takes place in stages i.e.
independently.
• After successfully connecting to other operations, the entire
chain progresses together. With a step-by-step reduction of
the time frame matching the customer requirement-weekly
schedules become daily, during this time the processes with
greatest weakness (most waste) will start appearing.
• This creates a cycle or a loop which can also be thought of as
a spiral as each cycle through the phases comes up with even
smaller quantities of waste.
• If periodic major changes are done in such situations
instability would be created and large improvements will
have to be done, starting all over again from the scratch, or
down the spiral.
Image Reference- The Toyota Way, Page 51
Thank You

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