2 Agenda Brief Overview of LEAN & LEAN Values What is Value Stream Mapping & BenefitsCase Study Value Stream Mapping – Case Study 1 & 2Various Examples Of Value Stream MappingAOB2
3 Agenda Brief Overview Of LEAN & LEAN Values What is Value Stream Mapping & BenefitsCase Study Value Stream Mapping – Case Study 1 & 2Various Examples Of Value Stream MappingAOB3
4 Processes and people with passion is key to continuous improvement. Brief Overview Of LEANCreate more value with less work by eliminating waste (TIMWOODT)Benefits include highly productive work force, satisfied customers and profitable operationsCreating a culture through continuous improvementPlanAccountability and OwnershipEnsure line management takes responsibility acting at top with functional supportActTrain and InvolveProvide customized ongoing training to close gaps in all Operations Excellence Building BlocksExcellence CultureCheckDoMeasure and RewardMeasuring stakeholder value by KPI’sEmployee incentives are linked to KPIsLeanOperations Building BlocksApply Operations Excellence Building Blocks in day to day OperationsProcesses and people with passion is key to continuous improvement.
5 LEAN Values Optimize The Whole Eliminate Wastes Learn Constantly Deliver FastEngage EveryoneKeep Getting Better Through Continuous Improvement5
6 What Is Value Stream Mapping & Benefits 1. Grasp current condition2. Identify problems within current condition3. Establish the ideal condition4. Set future target conditionPurposeProvides a detailed visual description of the current value streamProvides a detailed visual description of the current problems within the value streamProvides a detailed visual description of the ideal value stream achievable in an ideal worldProvides a detailed visual description of a redesigned target value stream as a compromise between current and ideal conditionsObjectivesShow a holistic view of the entire current systemVisualize material and information interactionsProvide common framework for discussionHighlight waste and its sources throughout the systemIdentify problems and their areaProvide common framework for discussionCreate a vision of an ideal lean value streamForce best practice thinking end-to-endSet baseline for tactical implementation planning by identifying value stream loopsPrioritize improvement efforts/actionsAssist in quantifying improvement potentialAllow target setting (short-mid-long term)
7 Agenda Brief Overview Of LEAN & LEAN Values What Is Value Stream Mapping & BenefitsCase Study Of Value Stream Mapping – Case Study 1 & 2Various Examples Of Value Stream MappingAOB7
8 Case Study 1 Imports Gateway VSM – Current State (2008) ORIGINSCEVA LHRCONSIGNEECUSTOMSSometimes cargoArr withoutPre-alertEXCELGSUPLUS DATAIMPATEX1Pre- Alert rcvd from OriginCheck Impatex for Dox rcvd and R/NA/L sets status 1 on our bond storeRcv Original Dox from courierOpen consol fileIf ours: Open Hawb file for Gen ImpSee Gen Imp MIFA1.6R/NAWBHAWBR/NOpen W/H file Receive P5 R/NOther Uk Offices:Capture in PLUSDo Inter Airport removal entryMake up pouch with docs & R/N – snd to W/HAdv dest that cargo readyDest staion arrange collectionR/NGen Imp cannot processTheir files before consol filesAre opened and putInto ImpatexKey out signed R/N and fileWkly bond check –match up with R/NWrite collection note for driversH/O to agents: Send docs to agentsCapture charges and inv agentWhen pd – change agent name in ImpatexAgent clears and coll from usIf storage, agent pays COD1Too many uncontrolledbuffersDriver fills vehicle log-collectsC/N1Update GSU with DTBW/H check inFrt arrives back to w/hC/N rtnd – key manf to Impatex (stat 1)Update GSU with ATA, OHDEnter charges in PLUSClose and file awaySee Gen Imp MIFALead time – Approximately 4 days
9 Case Study 1 Import Gateway– VSM After (2013) Shipment InformationShipment InformationOriginLHR HounslowDepartmentsOutlookMOFSImpatexExcelCoastwiseWI : 0006CT : 60CreateInvoice for HandoverWI : 0009CT : 90Re-nominations on ImpatexWI : 0008CT : 20Create Storage InvoiceWI : 0011CT : 90Consol on MOFSWI : 0018CT : 240OFS Doc’s for General importsWI : 0016CT : 35Receive Consol Pouch & Separate DocsWI : 0010CT : 35Create ERTS file (ERTS Process)WI : 0003CT : 95Create Customs records in ImpatexWI : 0004CT : 120Place in heijunka Box(ERTS Process)WI : 0013CT : 95Set inStatus 1WI : 0007CT : 90Key Out Release Notes on ImpatexWI : 0005CT : 30Retrieve P5 (ERTS Process)WI : 0012CT : 95Create Airline Col Notice (ERTS Process)WI : 0012CT : 95Lead Time 1 – 4 DaysVersion 2. 27/1/2014
10 Case Study 2 Pull and One Piece Flow Office-MIFAs updated, buffer symbols added and improvement bursts added-Target MIFA for Import and Export processes created- List of constraints generated10
11 Case Study 2 Pull and One Piece Flow Current Level:What was doneNext StepsEvidence of buffer management in placeKanban signals in place for warehouse processesConsiderable constraints towards achieving one piece flow exist in FM environmentProcesses observed and MIFAs updated for warehouse (FM, CL and Inventory) and FM officeModel department (warehouse) TNT Exports:Target MIFA produced (Volume Dependant Hours info not available)Constraint list to achieving one piece flow generatedKanban signal for sort process introducedModel department (office) Import:Target MIFA produced (24% Volume Dependant Hours) for import and exportKanban signals for shipments to be filed and problem customers introducedStationery re-order kanban system implemented and satellite stationery cupboard added to reduce walking distanceMirror warehouse kanban signal for TNT Import processRe-cycle time TNT Export sort process and calculate savingsMirror office kanban signals for Export department11Showcase Steering Committee Meeting – LHR
12 Agenda Brief Overview Of LEAN & LEAN Values What Is Value Stream Mapping & BenefitsCase Study Of Value Stream Mapping – Import Gateway (Transition)Various Examples Of Value Stream MappingAOB12
13 Global / UK Procurement – Tendering VSM SuppliersSite(s)EXCELOutlookNegotiateEngageEvaluateImplementMonitorLead time : 1 to 9 Months
16 IS&S VSM User IS&S Support Center User New User Change User OutlookOFSNew UserChange UserSystem Enhancement RequestIS&S TicketIS&S TicketClosedQuarterly User ReviewPrinter CreationDeleting BookingsGeneral Ticket SupportUnlocking BookingsStandards Change RequestChange Control16
17 1. LEAN – Standardized Work Visible Work Instructions Standardized work instruction sheetStandard description of procedureProcess step numberDescription of the process stepEach step is illustrated with a pictureBest in class example how to make work instructions visible.Revision control
18 Agenda Brief Overview Of LEAN & LEAN Values What Is Value Stream Mapping & BenefitsCase Study Of Value Stream Mapping – Import Gateway (Transition)Various Examples Of Value Stream MappingAOB18
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