Differences between Process Maps and Value Stream Maps
Value Stream Maps Include:
1. Value Add and Non-value Add of steps/activities
2. The Information flow along with the process flow to make the product 3. More information/data on the processes
4. Closed Circuit from the Customer back to the Customer
5. No Takt Time taken into account in process maps
Value Stream Maps
Information Flow goes from right to left while the process/material flow goes from left to right as seen below.
General information about VSM.
▪ Based on a today’s inventory level
▪ Inventory shifts every day but you should be capturing a snap shot to gain a basic understanding (It may shift a little over time) ▪ Look at your big customers and look at the critical components from your suppliers (Pick a representative or critical flow)
Material Flow Icons
Information Flow Icons
Possible List of Steps
The following is a list of steps that I generally follow but they may differ based on each scenario that is being modeled.
1. Title Block
It should go in the left hand upper corner and may include date, team members, what am I mapping, etc.
2. Customer Information
Who is the customer? What kinds of information are you getting from the customer? Place the customer near the upper right hand corner using the external source/factory symbol
3. Process Blocks
▪ Add the process blocks from raw material to finished product ▪ Use it to track transactional and/or manufacturing processes ▪ May include DCs as well during this step
▪ May include trucks for traveling between process
▪ Can include parallel and serial process flows as seen in figure below.
4. Data Boxes
Next place data boxes below each of the processes done in the previous step. What is going on in the process or what do you want to track in the process. Use any nomenclature that is appropriate for your organization. The following is a list of common used abbreviations with an example of a data box. | |[pic] | |C/T – Cycle Time | | |C/O – Change Over Time | | |U/T – Machine Uptime/Reliability | | |Y/R – Yield Rate | |
Make sure to leave enough room below the data boxes to add the value and non-value added times.
5. Add Inventory
Use the inventory (tombstone) to track significant inventory. Does not have to be in the same general location but maybe aggregated together as seen in the example below if the individual inventories do make sense (i.e., the inventory after process 1, in transit and before process 2 maybe combined into one tombstone. Also, the WIP maybe included if it is considered significant.
At this point these inventory levels should be in units that you all use at the various processes and may change as the materials are processed. This way as different people in the organization look at the map then you will be able to understand the inventory levels. See the figure below as an example from the textiles industry.
6. Customer Shipping
What, When, and How do we ship to our customer. Add this information to the map. This may include the DC at this point if not already added during building the processes in Step 3.
7. Supplier Shipping
Who is our supplier (s)? Add them using the factory symbol.
How do they get our raw materials to us (i.e., shipping, etc.)...
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