Page 79 - Lean six sigma demystified

58 Lean Six Sigma DemystifieD

Value stream mapping, flowcharting, and value-added flow analysis will help
you find ways to eliminate the delays between each step of the process. Employ-
ees won’t have to work any harder; you just eliminate the delay. The value
stream includes every activity required to deliver a product or service. Remem-
ber, only 5% of any slow-speed process adds value; 95% is non-value-added
effort and delay, what Toyota calls muda (“waste”).
The goal is to group all of the essential steps into work cells that encourage a
continuous flow with no excess inventory, wasted motions, interruptions, batches,
or queues. When you do this, the amount of people, time, technology, space, and
inventories required can be cut in half. To do this, start by listening to the voice
of the customer and evaluating how all of your activities support their needs.

Map the Value Stream

Purpose: Evaluate the existing or improved process as a starting point for
improvement.
1. Start by identifying customer needs and end with satisfying them.

2. Use square Post-it notes to lay out processes.
3. Use arrow Post-it notes to show delays.
4. Place activities in the correct order.
5. Identify inventory levels carried between each step.

I worked with one government organization that took 140 days to process a
request, but there were only 8 hours of actual work in the 140 days. Although
I thought it could be done in a couple of days, they reduced it to 30.

Spaghetti Diagrams

Spaghetti diagrams help detect crazy patterns of behavior in the production
workspace. Purpose: To examine the existing flow before redesigning it.

1. Use square Post-it notes to lay out a floor plan of machines or processing
stations.
2. Draw arrows to show movement of the product or service through the
floor plan.
3. Assess how many times each processing station is used. Is the highest vol-
ume closest to incoming materials or products?
4. Identify ways to redesign the flow to reduce unnecessary movement of
people and materials.