Value Stream Mapping, specially for process plants, aimed at identifying and eliminating avenues of Non-Value addition and optimizing Value Stream.
Value stream Mapping is one of the most important tool in Lean Management. Value Stream Mapping (VSM) was initiated by Toyota Motors and was used for many years to map material and information flow to identify non-value adding activities (waste). In present context of Indian Industry, VSM is effectively and widely used in Engineering and Automotive Industry as a tool in identifying non-value adding activities in process and optimize through-put time. At Adishree Tech Solutions, we have taken initiative to take VSM to process industries. While practicing VSM in process plants, we have selected a parameter of product manufacturing cost as a single factor for optimization. Through detailed analysis of product manufacturing cost, the extent of all processes, maintenance activities, materials in contributing to product value is analyzed. The analysis identifies Non-value adding processes/cost avenues and prioritizes all the activities based on their value adding capabilities. This forms a basis of next satge VSM. In next satge, improvement suggestions are evolved and their contribution in improving valus stream is analyzed.
The salient features of VSM carried out for process industries are as follows:
- Understanding present value stream :
- Subsequent to reaching complete understanding the product, processes and process set-up, direct observation at plants and detailed product cost structure ate THE TWO most important tools to identify Non-value adding processes/cost heads.
- Product cost structure identifies the materials, processes, showing potential of saving.
- Detailed, direct observation of plant and processes reveal the processes and support functions with improvement potential.
- Current State Map:
An effective tool to record present process and information flow.
- Value Optimization Proposals:
Well defined “Current State Map” forms a basis of analysis and evolution of improvement suggestions. The most common non-value adding activities are –
- In-process material spillages, cost to handle spillages, un-recoverable material loss.
- Energy loss in handling systems.
- Delays in providing Maintenance to plants/processes.
- Delays, errors due to manual operations in precision jobs.
- Under-utilization of manufacturing facilities, low parameters use, etc.
- The proposals for improving Value stream are complete with technical details (relevant Layouts, technical specifications, etc.), cost benefit analysis and implementation plans.
- We believe in providing support in implementation of proposals for improving Value Stream.
With proven experience, Adishree Tech Solutions carries out Value Stream Mapping in process plants (Cement Industry, Chemical, Metal and other process plants, Fiber Industries). We also provide VSM to Engineering/Automotive Industries.
