CreateASoft, Inc.
The Process Improvement Company

Using Simulation to Improve Value Stream Mapping.


Presented by

Hosni Adra
Product Manager/Partner

Introduction
 

• About CreateASoft, Inc.
  -- In business since 1992
  -- Provides software and simulation consulting services.
• Simcad Process Simulator
  -- Process modeling and simulation tool that is applied to multiple industries.
  
   

What Is Lean?

• Set of methods and concepts used to:
  -- Reduce waste.
  -- Decrease WIP.
  -- Provide a streamline flow.
• Lean concepts are not industry specific.
  -- Can benefit both the service and manufacturing environments.

Goals of Lean Systems

• Stabilize your processes.
  -- Review capabilities, labor, and material flow.
• Standardize processes and flow.
• Simplify through Kaizen principals.
  
  
  
  
   

Key Lean Concepts
 

• Takt time.
  -- Available production time/total quantity desired.
• Cycle time.
  -- Elapsed time from the beginning of the operation until completion, also known as processing time.
• Value added time.
• Non-value added time.
• Process efficiency.
  -- Value added time / total time.

Benefits of a Value Stream Map

• Gathers and displays a far broader range of information than a typical process map.
• Is at a higher level (5-10 boxes) than a typical process map.
• Is used at a broader level, from receiving of raw material to delivery of finished goods.
• Used to identify where to focus future projects, subprojects, and/or kaizen events.

A Value Stream Map
 

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Value Stream Map Limitations

• Static map.
  -- Changing the flow, product mix, resources, … requires a redefinition and revalidation of the map.
• One level – no layering.
  -- Inability to effectively show details where needed.
• Multiple map interaction can be difficult requiring a large effort.

Process Simulation

• Build and simulate based on the process map of the operation.
  -- A process can consist of multiple sub-processes (cells).
• Process and travel constraints can be defined in the model.
• Resource schedules, MTBF, carriers, and flow routings are defined.

The Role of Simulation

• Simulation provides a tool to analyze, visualize, and experiment.
• Test and analyze improvement ideas before implementation.
• Evaluate migration scenarios.
• Forecasting and scheduling.
  
  
  

Simulating a Value Stream?
 

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Dynamic Value Stream Mapping

• Values change based on input.
  -- Dynamic data display and update based on the model input.
• Process flow may change based on the input.
• Contains all the elements of the static map.

Benefits of Dynamic VSM

• Ease of validation.
  -- By changing the input to the flow, multiple scenarios can be tested.
  -- Product mix testing is simplified and expedited.
• Quick feedback on changes.
  -- Process flow changes can have positive or negative effect on the value stream.

The Role of Simulation

• By merging process simulation and value stream mapping
  -- Building a process flow results in a value stream map and vice versa.
• The dynamic behavior of the simulation environment lends itself to the dynamic value stream mapping.

Simulating Multiple VSMs

• Simulation tools (Simcad Pro) provide layering (cells) of the process flow.
  -- A cell can contain its own value stream map.
  -- Each cell can be analyzed and optimized independently.
• By connecting layers
  -- Output of one value stream can become the input to another.

Multiple VSMs

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Maintaining Improvement With Simulation

• A successful lean implementation requires:
  -- An updated value stream map that reflects the current state of the operation.
  -- An updated process map.
• Constant analysis of line modification.
  -- Validate that the change does not divert from the lean initiative.
  -- Analyze the change and reduce its impact on other sections of the operation.

Using Simulation
 

• By connecting the value stream map to the process map
  -- Change to one affects the other.
  -- Analysis and validation of one validates the other.
• Simulation is the best alternative for quick solution turnaround.
  -- Provided that both process map and value stream map are linked together to avoid duplicate work.
  
  
   

Simcad Pro Approach

• Integrated value stream map and process map.
  -- Computation of VAT, process efficiency, takt time deviation, and many others.
• Forecasting and scheduling.
  -- Load existing WIP, forecasted orders, and generate the best production schedule.
• Ease of model creation.
  -- Quick solution turnaround.
   

CreateASoft, Inc.
The Process Improvement Company

Using Simulation to Improve Value Stream Mapping.

Q & A

Contact information:
(630) 428-2850 x205 hadra@createasoft.Com