Throughout many first time Worth Stream Mapping workout routines, we now have seen some frequent errors. Many occasions when the error is made, it’s not acknowledged and the Worth Stream Mapping software is named into query. It is like making an attempt to make use of excel as a phrase processor, it sort of works however you simply do not fairly get the outcomes you have been anticipating. So listed below are a few of our observations.
1. You begin to comply with the individuals doing the work. All of us begin out understanding that we’re doing Worth Stream Mapping on a services or products nonetheless sooner or later, the individual doing the job leaves the product and does one thing else. Slightly than staying with the product we begin to comply with the individual. It could even seem to be we must always comply with the individual as the duty they’re doing is said to the product we’re following.
For instance in a dentist’s workplace, the product we are going to comply with is the affected person. The affected person is available in, they register, they sit down they usually wait. They get referred to as into the workplace and the dentist performs the work, they depart. The nurse takes their folder and does some work to it, she then works on the pc to replace the file and at last, she places the file away.
On this case we now have stopped following the affected person and we now have began to look at the work being carried out by the nurse.
2. Attempting to do a ultimate Worth Stream Map with out the services or products really being carried out. Everyone knows that it’s generally troublesome when you’re coaching individuals to do Worth Stream Mapping to all the time ‘see’ the product transfer by all the course of. It’s generally essential to go away the consumer with homework to truly observe the method and fill in all of the bins.
There are instances nonetheless the place corporations suppose that there’s not sufficient time to get a whole Worth Stream Map, the method is just too lengthy or will not be working for one more month and they should current to administration a financial savings plan by the tip of the week. They continuously suppose that they’ll go to their engineered requirements and fill within the info bins after which predict their financial savings serie gratuit.
On this case the individual has forgotten a number of the foundation of Lean. First with out observing the stock, they do not have a Worth Stream Map, they’ve a Course of Map. Second with out observing how the time requirements have been arrived at, how will you identify waste alternatives. Third the individual doing the work might have many distractions – for instance it could take me an hour to vary the brakes on a automotive however each time I begin, I’ve to do three oil adjustments. We have to observe the work and extra importantly what’s taking place to our product when the work is not being completed.
Workplace Worth Stream Mapping
A detailed relative of level quantity 2 is doing Worth Stream Mapping within the workplace. With a lot info on the pc as we speak, many corporations have all the knowledge on their processes and worth streams on their computer systems. If you wish to understand how many individuals are in an space we are able to get it, how a lot stock between processing steps and what the processing occasions are are all saved in actual time. Layouts of the plant flooring are saved and precise distances traveled might be calculated proper from the drawing. For a lot of corporations it actually is feasible to place a complete Worth Stream Map collectively in an workplace and for it to be technically appropriate.
Though the Worth Stream Map could also be technically appropriate we’re lacking the chance to look at what is occurring. For instance an organization knew from their customary pallet of fabric may very well be wrapped in 2 minutes and 30 seconds. They needed to be compelled out to the ground to truly observe the operation and to show they have been proper that they went on the market. What they noticed was the pallet took nearer to 25 minutes to finish as a result of the operator needed to reply four telephone calls. They did not understand that this was a part of the job of the operator.
In the event you do not observe, you’ll by no means determine why your lead-time is so lengthy. A lot of what takes place in day-to-day operations isn’t recorded in any customary. Issues like telephone calls, interruptions, or reprioritization of labor.
four. Double counting of time. It takes some time to grasp what to place into an info field and what’s a processing step. For instance Changeovers. We all know that they go into the knowledge field as a result of all of the books say so. Generally nonetheless individuals nonetheless ask why that point would not get recorded on the lead time line. How about journey time? I’ve to journey for 15 minutes between processing steps so I ought to have a field on my Worth Stream Map representing journey time. Ought to it’s counted as processing time? What will we embody in processing bins?
The important thing right here is to separate the issues that trigger stock to construct up, from the precise work to finish the half or service. Lengthy changeover occasions trigger stock to construct up, lengthy distances to journey trigger stock to construct up. Due to this fact these things are causes to be eradicated. They’re chargeable for the stock we see within the firm. We are going to account for them in our lead time calculation after we rely the stock.
Perceive the causes of stock construct up versus the precise steps to finishing a services or products for the client.
5. Ignoring shared assets. In most corporations there are assets which might be shared. These assets are required to assist a couple of product household. They might be individuals, meeting strains, gear, devices and many others. An instance can be a laboratory receiving space. They obtain the samples for a lot of labs and distribute them. If we overlook this throughout our Worth Stream Mapping course of we might get the incorrect outcomes.
Let’s select a easy instance. A receiving space receives samples for two labs. Every lab receives 80 samples a day. Due to this fact they obtain 160 samples and over an eight hour interval should provide every lab, 10 samples every. Due to this fact, they want 20 samples an hour and this requires 2 individuals. Throughout the Worth Stream Mapping, we mistakenly solely account for the one product households’ work. We imagine that they should provide solely 10 samples per hour and we solely require one individual for eight hours. This can be a easy instance and we’d in all probability catch it. Nevertheless, shall we say you’ve gotten a whole lot of merchandise and plenty of product households it’s possible you’ll miss this error.
Keep in mind to establish the shared assets. In the event you do not you’ll incorrectly calculate vital numbers just like the Takt time and cycle occasions.
6. Mixing product households. Someday when Worth Stream Maps begin to get actually complicated with many branching streams going out and in of the principle Worth Stream, it’s as a result of the individuals doing the Worth Stream Mapping did not do job of defining the product households earlier than beginning the Worth Stream Mapping. This drawback is mostly aggravated by one or each issues recognized earlier – both not figuring out a shared useful resource or following an individual and never the product. By not doing job with the product households we are able to get distracted and comply with the incorrect processing path.
For example we’re following a product household that solely goes by a lathe machine and is then shipped. The lathe may be utilized in a product household that goes to a welding and, then to an meeting space and onto a de-burring space and many others. If we’ve not correctly recognized the household we might begin to comply with the Worth Stream Map by meeting and de-burring after we ought to have gone from the lathe straight to the transport space.
Be sure you know your product households earlier than you begin Worth Stream Mapping.
These are usually not the one errors you may make throughout your preliminary Worth Stream Mapping periods; nonetheless they’re frequent to many corporations after they begin to find out about Worth Stream Mapping. Avoiding these errors will allow you to to make use of the Enterprise Worth Stream Mapping ® software higher. Like anything the extra you observe the higher you’ll get.