Map Where the Inventory Is..................................................................... 43
Map Where the Operators Are Located................................................... 44
Putting It All Together............................................................................... 44
Mapping Subtasks and Parallel Flows.............................................................. 45
Mapping Subtasks...................................................................................... 45
Mapping Parallel or Alternate Paths......................................................... 46
Lining Up Process Steps................................................................................... 47
Aligning the Process Horizontally............................................................ 48
Aligning the Process Vertically................................................................. 49
The Power of Speed......................................................................................... 50
5. Documenting Transactional Process Flow........................................ 51
Introduction........................................................................................................51
“The Product” in a Transactional World.......................................................... 52
Choosing the Level to Map............................................................................... 52
Understand the Focus of the Value Stream..................................................... 52
Start with the Workflow.................................................................................... 53
Mapping Subtasks and Parallel Tasks............................................................... 55
6. Showing the Flow Clearly................................................................. 57
Introduction....................................................................................................... 57
Providing Definition to Subtasks and Parallel Paths........................................ 57
Mapping the Reality of Rework........................................................................ 58
Using Terminators to Clarify Rework in the Flow........................................... 59
The Power of Simplicity.................................................................................... 62
7. Interpreting and Understanding Basic Product Flow...................... 65
Introduction....................................................................................................... 65
Showing Where Flow Starts and Ends............................................................. 65
The Traditional Mindset: Pushing Work.......................................................... 66
The Lean Concept of Pull Systems................................................................... 66
Controlling Material When Pull Is Not Possible.............................................. 68
Calculating Customer Demand and Takt Time................................................ 69
Showing Inventory............................................................................................ 71
Capturing Cycle Time........................................................................................74
Summarizing Basic Process Flow..................................................................... 76
Case Study in a Manufacturing Environment.................................................. 77
8. Utilizing Data in Manufacturing
. How to Add Power to Your Map with Facts.................................................79
Introduction....................................................................................................... 79
Record the Number of Operators for Each Process......................................... 80
Record the Cycle Time of Each Process Step.................................................. 81
Record the Changeover Time from One Process to Another.......................... 82
Record Uptime, or the Reliability of Equipment.............................................. 83
Record the Availability of Equipment............................................................... 85