Page 77 - Lean six sigma demystified

56 Lean Six Sigma DemystifieD

8 hrs Sales 8 hrs
Order Scheduler
Customer Sales rep
Kanban
CT = Cycle Time
CO = Change Over
UT = Up Time
1 = Inventory Supermarket
Kaizen
Process 1 100 Process 2 Process 3 Process 4
CT = 15 sec CT = 15 sec 100 CT = 15 sec 100 CT = 15 sec
Crew = 1 units Crew = 1 units Crew = 1 units Crew = 1
CO = 10 min CO = 10 min CO = 10 min CO = 10 min
Uptime = 100% Uptime = 100% Uptime = 100% Uptime = 100%
Waste = 5% Waste = 5% Waste = 5% Waste = 5%
Avaliable sec = Avaliable sec = Avaliable sec = Avaliable sec =
27600 1 day 27600 1 day 27600 1 day 27600
1 day 1 day 1 day
15 sec 15 sec 15 sec 15 sec
1 100
D units
a
y

FIGURE 2-5 • QI Macros value stream map.

• Requests for change may spend months in a prioritization cue before
being worked (non-value-added.)

• An order may sit idle waiting for an approval or material.
On a process flowchart or value stream map, most of the non-value-added
time will be found in one of three places.

• Arrows. Delay between process steps

• Rework loops. Fixing errors that should have been prevented
• Scrap processes. Discarding or recycling defective products