Future State Improve Kaizen Facilitation

Objectives Describe Ideal State Map Describe Future State Map Qualifying questions to utilize when analyzing Maps

Preamble Painting the Future The Current State Map is a snapshot in time – it’s where you are now. That’s an important view, but just part of the story. After you map your current situation, it’s important to set sights on where you are going. Let’s consider two future views: Ideal State: With only value-added steps, how could you best meet your customer’s requirements? (Sometimes referred to as “entitlement”) Future State: Incremental improvement – eliminating waste and reducing most non- value added steps

1) Ideal State Start with end in mind, see it all work perfectly Ideal flow, all activities are value-added No inventory, all steps produce perfectly, without errors or defects Exact capacity needed for consumption Correct number of staff Trained perfectly Ponder this: The Business Process is exactly right !

2) Future State Helps define activities for Kaizen effort Marry mapping efforts, analyses, and ideal state Improvements you select become foundation for your planning and improvement activities Future State Map is the next increment of performance improvement

Mark Up Current State Map Future State begins as a markup of Current State Make changes directly on the Current-State map Identify where and what type of improvements you intend to make Draw a “burst” (visual indicator) at the areas or steps you wish to improve Identify how many / how much NVA steps will be reduced, and how much process time reduced – estimate an improvement goal (quantify) 3 Potential Kaizen Events Identified

Mark Up Current State Map (continued) Improvement ideas (bursts) selected from the Detail Process Map and the PICK chart. These were the most crucial (Value-Added & Non Value Added but Necessary). From these ideas, the Future State Process Map is developed.

Seeing the Future As soon as you have identified the changes, create a new Process Map draft Picture what the Process Map will look like after implementing the improvements (Leave the Bursts for reference) Draw a new Future State

Steps to Develop Future State Map Identify start and end points. This helps set limits right from the start. Name the process. The process name should tell everyone what you are talking about. Add activities that are of value from previous charts. Add roles to activities . But don’t feel you need to get them all. You will be able to add them later. Document problems as they come up. Now, however, is not the time to discuss them or solve them.

Ask Qualifying Questions (where applicable) Indicate answers on the future-state map: What is the Customer demand? (takt time) Where is the bottleneck operations? Where can flow happen? Where will you utilize a signal for more material? Where does temporary storage need to be located? What is the right lot size between processes? What are the current change over times? How can schedule be smoothed? How is time being utilized?

Plan Improvements Step-by-Step Take actions identified on the Future-State Map and establish an implementation plan Plan should be concise Scope individual improvement activity Include timing and responsibilities Maintain scope and focus Address minimum number of key metrics Don’t try to solve everything at once Prioritize changes Follow through!

Review Update Current State to reflect New State This provides record of where you are After all ideas and improvements have been exhausted or you’re at end of planning period, start the mapping process again Use latest Current State Map, move through the exercise of creating a new Ideal-State (entitlement) and then building / planning improvements for the Future State Focus team actions on achieving Future State