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Value Stream Mapping Adapted to High- Mix, Low-Volume Manufacturing Environments 2012:120

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Value Stream Mapping Adapted to High- Mix, Low-Volume Manufacturing Environments 2012:120 Value Stream Mapping adapted to High- Mix, Low-Volume Manufacturing Environments 2012:120 JUAN MANUEL ARAYA Master of Science Thesis Stockholm, Sweden 2011 VALUE STREAM MAPPING adapted to HIGH-MIX, LOW-VOLUME Manufacturing Environments Juan Manuel Araya Master of Science Thesis INDEK 2011:x KTH Industrial Engineering and Management Industrial Management SE-100 44 STOCKHOLM Examensarbete INDEK 2011:x {Rapporttitel} {Namn1} {Namn2} Godkänt Examinator Handledare 2011-mån-dag {Namn} {Namn} Uppdragsgivare Kontaktperson {Namn} {Namn} Sammanfattning Nyckelord Master of Science Thesis INDEK 2011:x {Title} {Name1} {Name2} Approved Examiner Supervisor 2011-month-day {Name} {Name} Commissioner Contact person {Name} {Name} Abstract This research work proposes a new methodology for implementing Value Stream Mapping, in processes that feature a High-Mix, Low-Volume product base. The opportunity for adapting the methodology singularly for these types of environments was identified because implementing Value Stream Mapping as proposed in Learning to See features several drawbacks when implemented in High-Mix, Low-Volume. Although Value Stream Mapping has been proven to enhance many types of processes, its advantages are shrunk if they are implemented in High- Mix, Low-Volume processes. High-Mix, Low-Volume processes are types of processes in which a high variety of finished goods are produced in relatively low amounts. The high variety of finished goods causes several complications for the implementation of flow. The difficulties that prevent the flow are the following: • The variance in the products: With hundreds, or sometimes thousands of possible finished goods, the number of products causes a non-repetitive process. • The variance in the routings: All of the products that are produced can have completely different process routings, or order of stations it has to visit. This makes the application of production lines quite difficult. • The variance in the cycle times for each process. Each of the different products can have completely different capacity requirements at a specific machine, which limits the predictability of the process. This purpose of the thesis is to gather the best practices for controlling and improving High-Mix, Low-Volume processes and merge them with some innovative ideas to create an inclusive Value Stream Mapping methodology which is better fitted with the types of complications in High-Mix, Low-Volume environments. In parallel, the methodology is tested with the company: Boston Scientific, in their Ureteral Stents manufacturing process. The real-life experimentation will allow for the fine-tuning of the methodology, in order to truly create impact in the process. Dedicatory Although one person, the inspiration, knowledge, and methodology wrote this master thesis was really a team effort with many people aiding directly, or thru inspiration. Firstly, I would like to thank the staff at the Boston Scientific manufacturing plant. I would like to thank Enrique Saborio who initially contacted me with this great opportunity, and suggested the use of Value Stream Mapping as a possible project to develop. I thank Eric Tagarro, my supervisor for providing guidance, support, friendship, and most of all for the trust and freedom to have full control of the project. I would like to thank Juan Miguel Gomez for assisting me in every initiative, and the rest of the production team: Ernesto Trigueros, Juan Jorge Solano, Karoline Arguello, Nehemias Venegas, Ana Villalobos, Melissa Fernandez, and Kathya Centeno. The Industrial Engineering department consisting of Jean Paul Cerros and Tatiana Alvarado with whom I worked side-by-side. I would like to thank the rest of the US/DC production unit: every single person helped me with a situation at one time or another. I would like to thank Rocio Quiros at HR, for patiently helping me and guiding me through the bureaucratic process with the universities. I would like to thank everybody at Boston Scientific which I consider a great company, with an amazing, talented, and fun workforce. I would like to thank my IMIM family, including all of my classmates. They were the source of endless inspiration, competition, but most of all, endless fun in and outside the classroom. I consider all of them true lifelong friends with whom I look forward to sharing many more good times. I would also like to thank the IMIM Coordinators for all of their diligent efforts to provide the best experience possible. I would like to thank Professor Alberto Portioli for his interesting class in Lean Manufacturing, which provided with the initial knowledge base for the project. Also the rest of the professors from IMIM, I used topics from every single class in order to develop my project. Thank you for giving us this great knowledge. I would like to thank all of the innovative Lean Leaders who have written wonderful books, and have established an easy-to-understand methodology, proven to enhance business processes. Lastly, I would like to thank the most influential people in my life, my parents. They have unconditionally provided me support in everything I do, including the means to join the IMIM program, the best experience of my life. Every decision I take is based on their love and guidance. I also thank the rest of my family, especially my grandparents. Much love and blessings! Table of Contents Value Stream Mapping adapted to High-Mix, Low-Volume Manufacturing Environments .......... 1 1 Introduction ............................................................................................................................. 8 1.1 Problem Definition ........................................................................................................... 8 1.2 Purpose ........................................................................................................................... 10 1.3 Delimitations .................................................................................................................. 11 1.4 Target Group: ................................................................................................................. 12 1.5 Introduction to the Company and Research Setting ...................................................... 13 1.5.1 Company History: .................................................................................................... 13 1.6 Product Description ........................................................................................................ 15 1.7 Process Description ........................................................................................................ 16 1.8 Boston Scientific Ureteral Stents Portfolio ..................................................................... 17 1.8.1 Families .................................................................................................................... 18 1.8.2 Processes - Subassembly: ........................................................................................ 19 2 Development of Project at the Boston Scientific Ureteral Stents Line .................................. 22 2.1 Familiarization and Fact Finding Phase (3F Phase): ........................................................ 23 2.2 Polaris Pilot Phase ........................................................................................................... 23 2.3 Whole Line VSM Phase ................................................................................................... 24 2.4 Control and Documentation Phase: ............................................................................... 25 2.5 Final Project Plan: ........................................................................................................... 25 3 Definitions ............................................................................................................................. 26 4 Methodology ......................................................................................................................... 28 4.1 Scientific Research Paradigm .......................................................................................... 28 4.1.1 Design:..................................................................................................................... 31 4.1.2 Prepare: ................................................................................................................... 31 4.1.3 Collect: ..................................................................................................................... 31 4.1.4 Analyze: ................................................................................................................... 32 4.1.5 Sharing: .................................................................................................................... 32 4.2 Research Approach ......................................................................................................... 32 4.3 Research Method ........................................................................................................... 33 4.4 Sources of Information ................................................................................................... 33 4.5 Analysis of Findings ......................................................................................................... 34 4.6 Quality of Research ......................................................................................................... 34 4.7 Frame of Reference .......................................................................................................
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