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What is Extended Value Stream Mapping? - page 5 / 10

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Even at this minimum scope, note that the scale of maps changes dramatically between Learning to See (facility-level maps) and Seeing the Whole. The facility boxes that are the primary units of analysis in this breakthrough guide are the same size as the individual process boxes (“stamping”, “welding”, “assembly”) in Learning to See. Vast expanses of people and equipment within facilities have been shrunk into tiny boxes so we can see the big picture!

In this guide, we will draw maps with an intermediate field of view, starting at the distribution center for the completed product and proceeding upstream to raw materials (e.g., rolls of steel). For those with more ambition and with full cooperation from upstream facilities and firms, it is both possible and desirable to start near the end customer and work far back upstream toward raw materials.

Multiple Facilities Field of View — Seeing the Whole

Weekly

Weekly

Gamma HQ Production Control

MRP Buffalo, NY

14 days

Weekly

Beta HQ Production Control

MRP Cleveland, OH

Weekly

6 days

Weekly

Alpha HQ Production Control

MRP Plymouth, MI

Weekly

14 days

Weekly

Alpha Sales Order Bank

Birmingham, MI

10 days

Daily

6 days

6 days

Michigan Steel Service Co.

14 days

Dearborn Heights, MI Steel Coils

Gamma Plant Production Control

MRP Tonawanda, NY

6 days

Plant Production Control

Daily

Alpha Plant Materials Control

MRP

Alpha Plant Production Control

MRP

Alpha Distribution Center

Cleveland, OH

2x Week

2 x Week

2 x Week

Weekly

Daily

Daily

MRP Harlingen, TX

Weekly

Daily

Daily

Daily

1 x Day

960 / Day 640 A 426 ST 214 HT 320 B 213 ST 107 HT

6x Year

Gamma Stamping

2x Week

Beta Wipers Warehouse

1x Day

Beta Wipers Assembly

1x Day

Beta Wipers Cross-Dock

1x Day

Alpha Motors Cross-Dock

1x Day

Alpha Motors Assembly

500 m. Ship Batch = 1 Unit Train

TIME

STEPS

Total Steps

=

73

500 m. Ship Batch = 72 Coils Defective = 8%

0.3 d. 1

Tonawanda, NY

RM 336 h. WIP 110 h. FG 48 h. 3 Shifts 5 Days EPE = 3 Days Defects = 2000 ppm

20.6 d. (3131 s.) 22 (3)

2x Ye a r

1500 m. Ship Batch = 36 Pallets Defective = 6%

4.0 d. 1

Harlingen, TX

2.0 d. 4

5x Year

100 m. Ship Batch = 12 Pallets Defective = 6%

0.25 d. 1

Reynosa, Mexico

RM 56 h. WIP 41 h. FG 12 h. 2 Shifts 5 Days EPE = 1 Day

Defects = 400 ppm

4.6 d. (30 s.) 21 (3)

100 m. Ship Batch = 6 Pallets Defective = 3%

0.25 d. 1

Harlingen, TX

0.5 d. 4

600 m. Ship Batch = 6 Pallets

Defective = 3%

4.0 d. 1

2x

2000 m.

Ye a r

Ship Batch

= 6 Pallets

El Paso, TX

Defective = 3%

0.5 d. 4

4.0 d. 1

West Orange, NJ

RM 50 h. WIP 2 h. FG 14 h. 2 Shifts 5 Days EPE = 1 Day

Defects = 5 ppm

2.8 d. (120 s.) 11 (2)

960 Vehicles Defective = 1%

0.5 d. 1

Total Time

= 44.3 days

In-plant Time

= 31.0 days

Transport Time

= 13.3 days

Value Creating Time

= 3281 sec. 54.7 min.

Value Creating = 8 Steps

PART I: GETTING STARTED

5

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