Once you are through with the Pre-requisites for Creating Value Stream Map and decided for which Value Stream you are going to create VSM, gathered relevant team. Follow these steps to move ahead:-
You have two options to use for creating Value Steam Map 1) a mapping software such as Microsoft Visio, etc. and 2) On paper. Making it on a paper would be less time consuming as you will first need to develop fair level of skills to make it on a software. If you opt to do it on paper, arrange a butcher paper, some post it notes, a pencil and eraser as you will need to make changes a few times during the mapping process.
If it is first time creating VSM, You also need to make yourself familiar with few basic symbols used in VSM. These symbols are different from usual Process Map (Flowchart).
Step 1: Place the Customer at the Right: Since Lean is all about focusing on Customer needs, there is a logic behind putting the customer box first. Before getting into building internal process boxes you are first identifying the needs of the customer. Write down takt time as well. Put your external suppliers at the left side of the map.
Step 2: Add Process Steps Backward: Start placing the last activity / process box on your map. This will help you critically identify waste in your process in serving your customer needs. Move backward for placing more process boxes. Don’t make it too messy with lot of process boxes. A good idea is to avoid adding a box unless there is a hand-off between two different activities.
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Step 3: Add Process data attributes: Add the data or metrics relevant to your process such as Cycle Time, Error Rate, Uptime, Value Add Time, No. of People, etc. Remember, this exercise has to be done by actually visiting the workplace where production or relevant activity takes place to collect the first hand data. Guiding the team to gather this data would be more beneficial as they would be able to see with their own eyes the type and amount of waste happening and opportunities available for improvement.
Step 4: Document Queue times and Inventory for each activity: Put queue or inventory symbols between activities. This will help you identify the delays happening between different activities or functions.
Step 5: Draw in communication arrows: Now draw the communications arrows on how communication happens between different functions, departments or people. Is the communication manual or electronic. Use respective symbol.
Step 6: Add Push & Pull Arrows: Use these arrows between different activities or functions. This helps identify how product, information or material flow between different departments. Are things being pushed creating more waste or material or information being pulled based on customer demand. Pull helps reduce waste of overproduction.
Step 7: Add other data as needed: Discuss once again with the team and if required other data as needed. This may be On time delivery, Quality, etc.
Now that you have created your Value Stream Map it will not give you any benefit unless you analyse it to find out opportunities for improvement. Gather your team in order to analyse your value stream map. You may find help with our article 7 Easy Steps to Analyse Your Value Stream Map. Also you may need 8 Tips to Make Your VSM More Effective.
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