Creating a future state Value

Stream Map
How do you create a future state
value stream map?

Copyright Leanman 2015

Leanmanufacturingtools.org

Purpose of Value stream Mapping?

Tell us where we are?

Drive Improvement
Help us define an Ideal state
Provide a plan to move forward

Copyright Leanman 2015

Leanmanufacturingtools.org

Current State Value Stream Map

Monthly
forecast
Weekly
Order

Supplier

30 day
forecast
Daily
Order

Production
Control (ERP)

Customer
360 per Day

Weekly
Schedule

Weekly

Oven

Insertion

I
1860

Circuiit
Boarding

Washer

I
120

I
120

I
240

Daily

I
240

Final
Test

Final
Assy

Testing

I
120

I
180

Shipping

I
180

C/t = 60s

C/t = 120s

C/t = 60s

C/t = 60s

C/t = 60s

C/t = 60s

C/t = 60s

C/o =10m

C/o =0m

C/o =0m

C/o =0m

C/o =10m

C/o =5m

C/o =20m

U/t = 95%

U/t = 90%

U/t = 100%

U/t = 100%

U/t = 95%

U/t = 95%

U/t = 95%

Qual =95%

Qual =100

Qual =100% Qual =80%

Qual =98%

Qual =100%

Qual =98%0.5 days

5.2 days

60 Secs

0.3 days

0.3 days

120 Secs

60 Secs

0.6 days

0.6 days

60 Secs

0.3 days

60 Secs

Copyright Leanman 2015

Leanmanufacturingtools.org

Total process
time

0.5 days

60 Secs

Total Lead
time
8.Days

60 Secs

8 Mins

Why do we need an ideal state map?

A shared vision that everyone can agree to.
A target to aim for
An objective
Gets everyone working together towards a
common aim
Copyright Leanman 2015
Leanmanufacturingtools.org

Developing an Ideal state map

What would the ideal state be?
Be radical
Challenge what is possible
Consider the lean principles;

Value according to the customer

Identify the value stream
Make the value flow
Pull of the customer
Strive for perfection
Copyright Leanman 2015
Leanmanufacturingtools.org

Ideal State Map

Monthly
forecast
Supplier

30 day
forecast

Production
Control (ERP)

Customer
360 per Day

Production
Cell

Daily

Daily

Shipping

I
180

C/t = 60s

I
180

C/o =0m

0.5 days

U/t = 99%
Qual =99.9%

Copyright Leanman 2015

Leanmanufacturingtools.org

60 s

0.5 days

Total Lead
time
1.Day
Total process
time
1 Min

Reaching our ideal state

Need a plan or series of plans to reach our
ideal state
Define a future state; use kaizen bursts to
define the project
2-3 month duration projects maximum

Copyright Leanman 2015

Leanmanufacturingtools.org

Future state Value Stream Maps

May need several future state maps to move
from current to the ideal
Typical improvements;
Reduce Cycle Time
Reduce setups / reduce batches
Improve quality performance
Change delivery schedules
Implement kanban
Copyright Leanman 2015
Leanmanufacturingtools.org

Future State VSM

Monthly
forecast
Weekly
Order

Supplier

Weekly

Production
Control (ERP)

Oven

Insertion

I
1860

I
120

I
120

I
240

I
240

C/t = 120s

C/t = 60s

C/t = 60s

C/o =10m

C/o =0m

C/o =0m

C/o =0m

U/t = 95%

U/t = 90%

U/t = 100%

U/t = 100%

Qual =95%

Qual =100

Qual =100% Qual =80%

60 Secs

0.3 days

0.3 days

120 Secs

60 Secs

1. Get supplier to
make Daily
deliveries
2. Improve Quality
Performance from
80% to 95%+

Circuit
Boarding

Washer

C/t = 60s

5.2 days

Kaizen Bursts;

Weekly
Schedule

0.6 days

0.6 days

Use Kaizen Bursts to make

improvements to process
and define the next future
state map.

60 Secs

Copyright Leanman 2015

Leanmanufacturingtools.org

Moving towards our Ideal state map

As we complete our projects our future state
map becomes our new current state
Review the data boxes and inventory at the
end of each iteration
Reduction in Inventory and other improvements
will highlight more problems such as;
Machine reliability
Rework loops
Copyright Leanman 2015
Leanmanufacturingtools.org

Moving from Current State to Ideal State VSM

Through a series of future state
maps utilizing Kaizen Bursts we
move from Current state to our
ideal state map.

Copyright Leanman 2015

Leanmanufacturingtools.org

Copyright and Disclaimer

Any commercial use of this presentation and the content
therein is prohibited without prior permission. Requests for
permission to use can be made through the contact page of
http://leanmanufacturingtools.org/contact-page/
This presentation is for personal use only and cannot be
reproduced or circulated by anyone other than
www.leanmanufacturingtools.org
Content may be quoted or reproduced for private and
educational assignments as long as a proper citation is
given referring leanmanufacturingtools.org
The information within this presentation and website are
for information purposes only and any action taken is at
your own risk.
Create a future state value stream map;
contact through
leanmanufacturingtools.org for a
customized or editable version