Ascend to the Heights of Robotics and Automation with Value Stream Mapping
Ascend to the Heights of Robotics and Automation with Value Stream Mapping
If you were going to climb a mountain you would want to have a very definite map showing the best way to take to the top, basically a map. In implementing robotics and automation in your manufacturing operations you will want to have the best map to guide you to the top rung of efficiency and production. The value stream map seems to be very difficult to understand when you first look at it. Especially if this map that may have been completed by some else. But once you look into the detail of it, the map is an excellent representation of robotics and automation and how they are applied in business. The picture of the flow, which is VSM, into the operation of a business gives you a perfect way to focus on the flow and eliminate waste in your operation.
The value stream that is mapped is the picture of all the elements that impact a product as it travels through the manufacturing processes. Elements that add value in the processes and those that do not add value are included in the picture. This picture will "see" all parts of the process from the time that raw materials come into the facility until the finished product goes out the door. The VSM will focus only on those areas inside your operation over which you have control.
There are two main objectives for using the VSM. First, it will allow you to lay out the optimum arrangement of robotics and automation in your facility. Second, it will identify areas where waste can be eliminated, making the manufacturing much more efficient. The graphical representation in the VSM shows two distinct flow movements. The actual movement of the material from one work center to the next is seen, but also the flow of information that supports the work is seen. It is very important to see both of these in an accurate VSM.
The map of robotics and automation in your business is created in stages. If you have an existing operation with currently running automation, you need to make a VSM that shows the current flow of information and material in your business. This gives you the starting point to start your climb to the optimum heights of robotics and automation. If you are starting a manufacturing operation then you will be starting off charting the future phase of the VSM. This map is the VSM that an existing business wants to go toward, with robotics and automation that will yield reduced waste and quality product output. Once the future VSM is created it is important to create an action plan based on this VSM and then execute it.
There is a specific order to the creation of parts of the the VSM. These parts are:
Select a product family to map - In selecting a product family for creating the VSM, the value stream should be defined from the customer standpoint. Any product that is within the family must pass through similar manufacturing processes. The customer can be internal or external. You should be sure and list all of the part numbers that are used in the stream.
Form a VSM team - A team of employees must be assigned to the VSM creation. The leader of the team should be from the line management ranks and have enough authority to effect change in the organization. The team should be made up of personnel who know the product family well, are from several disciplines within the company, and they should be trained in VSM.
Understand customer demand for the product family - Understanding of customer demand for the product family is the best starting point for the VSM team. One of the best places to find such information is production control where there are usually weekly and monthly forecasts for products and their parts. Production history for the product family is another place. The team can look at comparisons from day-to-day and month-to-month. Sales forecasts and new business details can give some other insight. Be sure to include every part that is used in the production process in the VSM.
Map the process flow The process flow for the VSM includes all the working areas that are involved in manufacturing the product. The flow will move from left to right on the page. All of the attributes that impact the process at any given work station should be included in the graphics. A typical process flow for a VSM is as follows:
Map the material flow In building the material flow map you should observe all the places where the flow of raw materials stops in the movement through the manufacturing processes. These points will be inventory points in your production cycle. The material flow should look like this:
Map the information flow An important part of the manufacturing process is the supporting information that is required to keep the devices performing the tasks that need to be done. Production control should be having two-way conversations with not only the devices in production, but also the customers and suppliers of the company. Suppliers will be receiving forecasts and orders for raw materials for production. Customers will be sending forecasts and orders for products that are needed. That flow should look like this:
Determine total product cycle time Looking at what time has been required in each step of the manufacturing process should help to determine what the total product cycle time is. The time for each step in the process should be geared toward producing products so that the demand for those same products can be met exactly by production. That time line should look like this:
Building the VSM will assist your company in accurate definition of manufacturing devices that must be put into place for efficient production. VSM will also help you avoid accumulated inventory in places that it should not accumulate.