How to Get Started with a Current State Map
Step 1 – To start a Current State map, the first item of business is to obtain customer information and delivery schedules. The whole concept of LEAN is based upon meeting customer demand and how to achieve this. In order to meet that demand, the first thing that will need to be done is to understand what that demand is and how quickly the production cycle must work to meet that demand.
Step 2 – The next step is to perform a quick walk through of the production floor to identify the main processes (in order).
As you begin the process of documenting the Current State map, some of the information to consider gathering from the shop floor should be:
- Number of product variations
- Cycle time ( from 1 piece to the next)
- Changeover time
- Process reliability
- Number of operations
- Scrap rate
- Production batch sizes
- Working time (minus breaks)
- Pack size
- Others
By gathering this information through your walk through process, valuable information can be obtained as to inefficiencies from the shop floor processes.
Step 3 – The next step in the process is to begin the actually documentation of the Current State map. This workflow documentation can be completed through use of data boxes and inventory icons and triangles that can be obtained from LEAN document sources or through internal development.
Step 4 – Once the Current State map is outlined, the next step is to obtain supplier information to determine how and when supplies are purchased, inventoried, and ultimately used for production. Idle supplies and raw inventory is considered non-utilized cash that could be freed up for other processes or functions. Understanding how supplies are ordered and utilized will help to free up this idle cash flow.
Step 5 – The next step is to determine basic information flow. More specifically, how do processes know what to make next. Avoiding overproduction is a key element of LEAN. Overproduction will tie up cash flow as well as over utilize production for inventory that is not necessary compared to a product or line that may be under producing for a client.
These steps will allow for production managers and machine operators to identify where materials are being pushed. The intent of Value Stream Mapping is to eliminate the push of materials and move to a pull system for materials and production. A pull system is dictated by client demand. A push system is dictated by how much the facility can actually produce. A push system is not client driven but company driven, meaning that client demands are typically not met.