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LEAN METHODOLOGY VALUE STREAM MAPPING (VSM) Version: 1.

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Presentation on theme: "LEAN METHODOLOGY VALUE STREAM MAPPING (VSM) Version: 1."— Presentation transcript:

1 LEAN METHODOLOGY VALUE STREAM MAPPING (VSM) Version: 1

2 Agenda Brief Overview of LEAN & LEAN Values What is Value Stream Mapping & Benefits Various Examples Of Value Stream Mapping 2 Case Study Value Stream Mapping – Case Study 1 & 2 AOB

3 Agenda Brief Overview Of LEAN & LEAN Values What is Value Stream Mapping & Benefits Various Examples Of Value Stream Mapping 3 Case Study Value Stream Mapping – Case Study 1 & 2 AOB

4 Brief Overview Of LEAN Create more value with less work by eliminating waste (TIMWOODT) Benefits include highly productive work force, satisfied customers and profitable operations Creating a culture through continuous improvement Excellence Culture Lean Train and Involve Provide customized ongoing training to close gaps in all Operations Excellence Building Blocks Plan Do Check Act Operations Building Blocks Apply Operations Excellence Building Blocks in day to day Operations Measure and Reward Measuring stakeholder value by KPI’s Employee incentives are linked to KPIs Accountability and Ownership Ensure line management takes responsibility acting at top with functional support Processes and people with passion is key to continuous improvement.

5 LEAN Values Optimize The Whole Eliminate Wastes Deliver Fast 5 Learn Constantly Keep Getting Better Through Continuous Improvement Engage Everyone

6 What Is Value Stream Mapping & Benefits Provides a detailed visual description of the current value stream 1. Grasp current condition Objectives Purpose Show a holistic view of the entire current system Visualize material and information interactions Provide common framework for discussion Highlight waste and its sources throughout the system Identify problems and their area Provide common framework for discussion Provides a detailed visual description of the current problems within the value stream 2. Identify problems within current condition Create a vision of an ideal lean value stream Force best practice thinking end-to-end Provides a detailed visual description of the ideal value stream achievable in an ideal world 3. Establish the ideal condition Set baseline for tactical implementation planning by identifying value stream loops Prioritize improvement efforts/actions Assist in quantifying improvement potential Allow target setting (short-mid- long term) Provides a detailed visual description of a redesigned target value stream as a compromise between current and ideal conditions 4. Set future target condition

7 Agenda Brief Overview Of LEAN & LEAN Values What Is Value Stream Mapping & Benefits Various Examples Of Value Stream Mapping 7 Case Study Of Value Stream Mapping – Case Study 1 & 2 AOB

8 HAWB AWB Case Study 1 Imports Gateway VSM – Current State (2008) ORIGINS CONSIGNEE CEVA LHR CUSTOMS PLUS DATAIMPATEXGSUEXCEL Pre- Alert rcvd from Origin Check Impatex for Dox rcvd and R/N A/L sets status 1 on our bond store Open consol file Rcv Original Dox from courier H/O to agents: Send docs to agents Do Inter Airport removal entry Other Uk Offices: Capture in PLUS If ours: Open Hawb file for Gen Imp See Gen Imp MIFA Key out signed R/N and file Dest staion arrange collection Adv dest that cargo ready Make up pouch with docs & R/N – snd to W/H Open W/H file Receive P5 R/N When pd – change agent name in Impatex Capture charges and inv agent C/N rtnd – key manf to Impatex (stat 1) If storage, agent pays COD Agent clears and coll from us Frt arrives back to w/h Driver fills vehicle log- collects Write collection note for drivers Enter charges in PLUS Update GSU with DTB Update GSU with ATA, OHD Close and file away W/H check in See Gen Imp MIFA Wkly bond check – match up with R/N R/N C/N R/N Sometimes cargo Arr without Pre-alert Too many uncontrolled buffers Gen Imp cannot process Their files before consol files Are opened and put Into Impatex Lead time – Approximately 4 days 1 1.6 1 1

9 Case Study 1 Import Gateway– VSM After (2013) OriginLHR HounslowDepartments OutlookMOFSImpatexExcel Receive Consol Pouch & Separat e Docs WI : 0010 CT : 35 Coastw ise WI : 0006 CT : 60 Create Invoice for Hando ver WI : 0009 CT : 90 Re- nomina tions on Impate x WI : 0008 CT : 20 Place in heijunk a Box(ER TS Process ) WI : 0013 CT : 95 Retriev e P5 (ERTS Process ) WI : 0012 CT : 95 Create ERTS file (ERTS Process ) WI : 0003 CT : 95 OFS Doc’s for Genera l import s WI : 0016 CT : 35 Version 2. 27/1/2014 Create Airline Col Notice (ERTS Process ) WI : 0012 CT : 95 Create Custom s records in Impate x WI : 0004 CT : 120 Shipment Information Lead Time 1 – 4 Days Set in Status 1 WI : 0007 CT : 90 Key Out Release Notes on Impate x WI : 0005 CT : 30 Create Storage Invoice WI : 0011 CT : 90 Consol on MOFS WI : 0018 CT : 240

10 10 - MIFAs updated, buffer symbols added and improvement bursts added - Target MIFA for Import and Export processes created - List of constraints generated Case Study 2 Pull and One Piece Flow Office

11 11 Mirror warehouse kanban signal for TNT Import process Re-cycle time TNT Export sort process and calculate savings Mirror office kanban signals for Export department Current Level: Evidence of buffer management in place Kanban signals in place for warehouse processes Considerable constraints towards achieving one piece flow exist in FM environment Processes observed and MIFAs updated for warehouse (FM, CL and Inventory) and FM office Model department (warehouse) TNT Exports: Target MIFA produced (Volume Dependant Hours info not available) Constraint list to achieving one piece flow generated Kanban signal for sort process introduced Model department (office) Import: Target MIFA produced (24% Volume Dependant Hours) for import and export Constraint list to achieving one piece flow generated Kanban signals for shipments to be filed and problem customers introduced Stationery re-order kanban system implemented and satellite stationery cupboard added to reduce walking distance What was doneNext Steps 11 Case Study 2 Pull and One Piece Flow Showcase Steering Committee Meeting – LHR

12 Agenda Brief Overview Of LEAN & LEAN Values What Is Value Stream Mapping & Benefits Various Examples Of Value Stream Mapping 12 Case Study Of Value Stream Mapping – Import Gateway (Transition) AOB

13 UK ProcurementSuppliersSite(s) Lead time : 1 to 9 Months Global / UK Procurement – Tendering VSM EXCELOutlook NegotiateEngageEvaluate ImplementMonitor

14 Finance Operations – VSM LHR Hounslow EXCEL LHR Unbille d WI:LHR002 CT : 600 LHR P&LN WI : LHR003 CT : 600 Interco mpany WI : DM001 CT : 300 LCRVO/ DFM WI : DM004 CT : 240 Version 2. 27/1/2014 OUTLOO K SharePoi nt / Shared Drive Shipment Information Lead Time 5 – 48 hours Cycle Time Seconds

15 Export Gateway – VSM UK BranchesLHR GatewayCEVA Destination Outlook OFS Receive Booking Instructions WI : 001 CT : 120 Create MAWB WI : 002 CT : 300 Version 2. 27/1/2014 IMPATEX Shipment Information Lead Time 1 – 4 Days Complete HAWB WI : 003 CT : 120 Complete & Close MUCR Entry WI : 004 CT : 240 Splitting Docs WI : 005 CT : 240 Accounting MAWB WI : 006 CT : 120 Post Flight & Navigator WI : 007 CT : 240 Navigator Cycle Time 1380 Seconds

16 IS&S VSM UserIS&S Support Center User 16 OutlookOFS Printer Creation Quarterly User Review New User Change User System Enhanceme nt Request Deleting Bookings Unlocking Bookings General Ticket Support IS&S Ticket Closed Standards Change Request Change Control

17 1. LEAN – Standardized Work Visible Work Instructions Standardized work instruction sheet Standard description of procedure Process step number Description of the process step Each step is illustrated with a picture Revision control 17

18 Agenda Brief Overview Of LEAN & LEAN Values What Is Value Stream Mapping & Benefits Various Examples Of Value Stream Mapping 18 Case Study Of Value Stream Mapping – Import Gateway (Transition) AOB


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