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Achieving and Maintaining Lean in the Job Shop
CreateASoft, Inc.
The Process Improvement Company



Hosni Adra
Process Improvement Manager/Partner
About CreateASoft, Inc.
  • In business since 1992
  • Core technology: Simcad Process Simulator software
  • Provides Simulation and Process Improvement services to the manufacturing and service industries in the areas of
  • Automation, manufacturing, and process improvement.
  • Lean transition and implementation.

Simcad Process Simulator
  • Discrete-Event based process simulator with extended continuous simulation capabilities.
  • Design and developed in the US by CreateASoft, Inc.
  • Currently includes Dynamic VNM/VSM.
  • Will integrate with PFAST.
  • Currently used by many companies,
    Jostens, Baxter, USAF, Bechtel SAIC, The US Department of Energy, Rumble Automation, LaSalle Bank, Florida hospital and many others..
 
 
 
Why Lean?
  • Benefits of lean
    Improve efficiency.
    Decrease and control lead time.
    Remove waste.
    Increase “on-time” delivery
    Reduce WIP
    • .....
  • Happier customers, better work environment, less stress, Reduce production cost.
 
Key to Lean success
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Lean Approach
  • Lean initiative is a constant improvement cycle.
  • Build a value stream, process flow.
    Goal is to analyze the operation
    Identify waste
    Prioritize improvement project
  • Analyze improvement impact
    Complete the Kaizen(s)
    Prioritize the next Kaizen(s).
 
The Value Stream Map
  • Process flow
  • Displays flow characteristics
    Process constraints and performance.
    Timeline – Helps identify total waste time.
  • Help in identifying the critical path.
  • Good documentation tool.
 
Issues with VSM
  • Has a tendency to grow too large
    Many value streams span multiple “walls”
  • Contains “static data”
    How does the value stream change when the process flow or product mix changes.
    Impact on the rest of the value stream (Up stream and down stream)
  • Good for static environment, but can be challenging otherwise. (the Toyota model)
 
Simplifying the VSM
  • VSM can be simplified through the use of layers.
    Patented technology developed by CreateASoft*.
    Allows the value stream to be viewed at varying levels of detail.
       One Stream can act as the supplier or consumer to one or more streams.
      Each Layer can be represented as a single process or a collection of processes.
  • Enhances the visibility and representation of the VSM.
  • Forces the interaction requirement between multiple VSMs.
 
The Value Network Map
  • High mix/Low volume the value stream changes based on the current production schedule.
  • The value network map displays information per product family for each process
    Provides greater visibility into the value stream.
    Helps identify “Waste” areas.
    Prioritize Kaizen events.
  • Ability to single out a product or a combination of products for more in depth analysis.
 
Example of a VSM Layers

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A VSM Layer
 

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The Role of Dynamic VSM/VNM
  • Issues facing the Job shop:
    Routing will vary per Job.
    Job Mix varies constantly.
    Resource allocation issues.
    Lead time control – When can we deliver ?
  • Dynamic VSM/VNM updates the contents of the VSM/VNM based on the input constraints, without user interaction.
  • Example.

Impact on the Big Picture
  • By allowing the VSM/VNM to be dynamic, flow constraints and routing changes have a direct impact on results.
  • Lead times, VAT, waste time are automatically identified.
  • “Critical path” is computed.
  • Interactions between multiple streams is simulated, with problems dynamically identified.
  • Faster Results, better control over the operation.
 
The Job Shop schedule
  • The presence of monuments increases the complexity of the schedule.
  • Scheduling must be dynamic
    Priorities, job status, impact of other equipment.
  • Must maintain the “waste” reduction achieved in the Kaizen events.
  • Optimize the “Monument” efficiency and reduce change over time.
 
Tools/Examples
  • Dynamic Simulator (s)
    Constantly forecast the future of the value stream.
    Update schedule based on current state.
  • Dynamic creation and tracking of the Value network map.
  • Use of RFID or Barcodes
    Tie in with the simulator to provide ultimate results. Can provide “Virtual Camera” into the operation.
 
CreateASoft, Inc.
The Process Improvement Company

Achieving and maintaining Lean in the Job Shop

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