Work-in-Process (WIP) Value Stream Flow Kaizen Objectives:
- Familiarize kaizen team with just-in-time production principles & methodologies
- Assist team members in "seeing the flow" of their "Model" value stream
- Create a comprehensive current state value stream map of the company's "model" value stream's flow
- Assist kaizen team members in understanding how lean principles and practices can significantly improve flow within the "model" value stream
- Assist team members to visualize, then design an aggressive, yet feasible future state improvement design and an effective transformation plan
- Assist team members in developing an effective JIT materials management and visual production management mechanism for their "model" value stream
To achieve these objectives, kaizen team members will:
- Practice, through discussions and case study illustration, basic value stream flow mapping, kaizen concepts, team building, and value stream management
- Develop, both current and future state maps of the company's focus "model" value stream
- Learn value stream kaizen process leadership roles and responsibilities
A manufacturer's work-in-process (WIP) value stream includes all actions required to bring a product from receipt of raw materials through shipment to customers.
Each action in this chain of activities is either value adding (e.g., Being machined) or non-value adding (e.g., waiting to be cleaned). "Seeing" your manufacturing processes from a value stream perspective means looking at the forest at fifty feet, not its individual trees. It means paying attention to improving the system as a whole. Dock-to-dock, rather than focusing on individual process stages.
By creating a current state map (how we do it now) you create a "visual" of production flow. From this baseline, you can apply lean principles to create an improved future state (how we want to do it) vision of an ideal value flow.
Value Stream flow kaizen is a simple process. You map the process, using pencil and paper right on the shop floor, by following products, dock-to-dock, carefully drawing a visual portrayal of each process in the flow of work-in-process, materials, and information.
The results will be eye opening, revealing improvement conditions and opportunities which might otherwise go unnoticed. Then an improved future state (and how to get there) can be visualized and planned.