Steps
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Tasks
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Tools
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1. Value
Specify value.
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- Identify who the customers are, both externally and internally.
- Define value from customer's point of view.
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- Value documentation form
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2. Value Stream
Identify value stream and eliminate waste.
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- Observe tasks and times.
- Document and understand process steps and types of work (value added, necessary non-value added and waste)
- Document waste in each category: Overproduction, waiting, transportation (unnecessary materials, products or information), overprocessing, unnecessary inventory, motion (people) and defects
- Conduct root cause analysis.
- Implement error-proofing processes.
- Create current state value stream map.
- Eliminate steps that do not add value.
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- SIPOC model
- Process flow diagram
- Task and Time Observation Sheet
- Waste Walk Checklist
- Value stream mapping symbols
- Value stream map
- Cause-effect diagram
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3. Flow
Ensure work flows smoothly from one stage to another.
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- Ensure work is balanced for process stages.
- Calculate takt time [Required mean service rate] [Takt Time (Rate) = Available time/ demand]
- Improve layout and visual controls.
- Implement the 5S workplace:
- Sort [Remove unnecessary items from area.]
- Set in order [Organize items that remain.]
- Shine [Clean, paint, replace or cover up.]
- Standardize [Use standardized procedures to maintain benefits.]
- Sustain [Ensure discipline occurs to maintain the workplace.]
- Design quick-change-over methods.
- Reduce work-in-process.
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- Mistake proofing tools
- Sign boards to signal replenishing needs
- Visual work tools
- Daily process performance
- Use the Five Whys (5Ws)
- SIPOC model
- Little's law: Throughput time = work in process amount/average completion rate
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4. Pull
Customer pulls what is needed.
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- Create standard work processes.
- Move items only when needed by customer.
- Implement just-in-time (JIT) production.
- Implement JIT supply.
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- Visual workplace systems, pull systems and just-in-time (JIT) processes.
- JIT tools for right items at the right time
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5. Perfection
Continue reducing waste.
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- Create continuous improvement by changing processes to eliminate new waste and new delays found in work.
- Always look for ways to reduce more waste.
- Use kaizen (continuous improvement) events.
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- Visual controls that show waste
- Management reviews to control the workplace
- Tools for documenting and eliminating waste
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