Lezione 4C - CREAZIONE VSM - Parte 3 di 4 - Lean Thinking e Toyota Producition System - Zero sprechi

Summary

The script discusses the process of selecting product families and grouping them based on similar processes. It provides an example with inspection, cleaning, and assembly processes shared among different products. The speaker then outlines the main tools for drawing a business process map, including various symbols for processes, data, and inventory. The steps for creating a value stream map are detailed, emphasizing the importance of defining product families before mapping. The script also covers how to calculate lead time, cycle time, and efficiency, and suggests using physical paper for mapping to visually represent processes and data.

Takeaways

• 🔍 **Identify Product Families**: Group products and services that share similar processes to streamline operations.
• 📊 **Create a Business Process Map**: Define product families first to map out a visual business process for each.
• 🛠️ **Use Key Tools for Mapping**: Utilize basic tools like process boxes, data boxes, arrows for transportation and information, FIFO lanes, and inventory symbols.
• 📈 **Start with客户需求**: Begin mapping with customers and suppliers to understand the demand flow.
• 📅 **Incorporate Frequency and Timing**: Include weekly and daily demand calculations, and transportation frequencies from suppliers.
• 🔄 **Add Processes and Data Flow**: Add processes and data flow from left to right to maintain a logical sequence.
• 📏 **Measure Inventory Levels**: Calculate inventory levels in terms of both quantity and days of supply.
• ⏱️ **Lead Time Calculation**: Determine lead times which are crucial for understanding process efficiency.
• 📉 **Efficiency Analysis**: Calculate the process efficiency by comparing total cycle times with total lead times.
• 📝 **Documentation is Key**: Record all process details, including personnel, shifts, cycle times, and changeover times.
• 🖼️ **Visual Representation**: Use physical or digital tools to create a comprehensive visual map of the business processes.

Q & A

What is meant by 'product families' in the context of the script?

Product families refer to groups of products or services that undergo similar processes. In the script, examples include chains, baskets, and sheets which share processes like inspection and cleaning.

Why is it important to define product families before designing a business stream map?

Defining product families is essential because each family will have its own visual stream map. Grouping products based on their shared processes allows for more efficient mapping and analysis of workflows.

What are the key tools used for designing a visual stream map?

The key tools for designing a visual stream map include a process and data box, different types of arrows (push and transport), FIFO lanes (First In First Out), manual and electronic information arrows, and symbols representing suppliers, customers, and inventories.

What is the significance of the yellow triangle symbol in a visual stream map?

The yellow triangle in a visual stream map represents 'work in progress,' either in terms of physical goods or information, indicating the current status of ongoing tasks.

How are customer and supplier interactions incorporated into the stream map design?

Customer and supplier interactions are the starting point for the stream map design. First, the demand is calculated based on weekly or monthly schedules, and transport from the supplier is illustrated, including frequency and delivery details.

What role does lead time play in the visual stream map?

Lead time represents the time it takes to complete a product cycle. It is a key factor in the stream map and is calculated by dividing the number of pieces by the cycle time, which is then converted into days to assess overall efficiency.

What is the purpose of adding a timeline at the bottom of the stream map?

The timeline at the bottom of the stream map shows the time needed for each process, including cycle times and inventory days, providing a visual representation of the overall time required for production.

How is process efficiency, or 'process cycle efficiency,' calculated in the visual stream map?

Process cycle efficiency is calculated by dividing the sum of the cycle times by the sum of the lead times. It indicates how efficiently the production process is operating in comparison to the total time available.

What is the role of colored sticky notes in designing a physical visual stream map?

Colored sticky notes are used to highlight different aspects of the production processes on the stream map, such as process names, data, customers, and suppliers. Each color signifies a distinct characteristic to make the map more organized and understandable.

What specific data are typically filled into the boxes on the stream map?

The data filled into the boxes usually include the number of workers, shifts, cycle time (CT), lead time, changeover time (setup time), availability, and quality rate (good pieces vs. total produced pieces).