Product Development Value Stream Mapping (PDVSM) Manual Release 1.0 September 2005 Hugh L. McManus, PhD The Lean Aerospace Initiative Sept. 2005 Product Development Value Stream Mapping (PDVSM) Manual 1.0 Prepared by: Dr. Hugh L. McManus Metis Design 222 Third St., Cambridge MA 02142 [email protected] for the Lean Aerospace Initiative Center for Technology, Policy, and Industrial Development Massachusetts Institute of Technology 77 Massachusetts Avenue • Room 41-205 Cambridge, MA 02139 The author acknowledges the financial support for this research made available by the Lean Aerospace Initiative (LAI) at MIT, sponsored jointly by the US Air Force and a consortium of aerospace companies. All facts, statements, opinions, and conclusions expressed herein are solely those of the author and do not in any way reflect those of the LAI, the US Air Force, the sponsoring companies and organizations (individually or as a group), or MIT. The latter are absolved from any remaining errors or shortcomings for which the author takes full responsibility. This document is copyrighted 2005 by MIT. Its use falls under the LAI consortium agreement. LAI member companies may use, reproduce, and distribute this document for internal, non-commercial purposes. This notice should accompany any copies made of the document, or any parts thereof. This document is formatted for double-sided printing and edge binding. Blank pages are inserted for this purpose. Color printing is preferred, but black-and-white printing should still result in a usable document. TABLE OF CONTENTS ACKNOWLEDGEMENTS........................................................................................................ 7 ABOUT THIS VERSION........................................................................................................... 7 1.0 INTRODUCTION AND SCOPE.......................................................................................... 9 Scope...................................................................................................................................... 9 Using this Manual................................................................................................................. 10 2.0 LEAN ENGINEERING PROCESS IMPROVEMENT....................................................... 13 Focus on Engineering Process............................................................................................... 13 Engineering Processes Need Improvement............................................................................ 14 Engineering is Different........................................................................................................ 17 Summary .............................................................................................................................. 20 3.0 GETTING STARTED ........................................................................................................ 21 Identifying Key Stakeholders................................................................................................ 21 Defining the Team................................................................................................................ 23 Training the Team ................................................................................................................ 24 Bounding the Problem .......................................................................................................... 24 EXAMPLE: Getting Started.............................................................................................. 25 Defining the Value................................................................................................................ 27 METRICS: Output Value.................................................................................................. 29 EXAMPLE: Value and Metrics......................................................................................... 29 Understanding Value Creation .............................................................................................. 30 METRICS: Value Creation ............................................................................................... 31 Aspects of Value................................................................................................................... 32 EXAMPLE: Value Aspects............................................................................................... 34 Summary .............................................................................................................................. 35 4.0 MAPPING THE CURRENT STATE VALUE STEAM...................................................... 37 Basic Advice for Mapping the Current State ......................................................................... 38 The Zeroth Map (optional).................................................................................................... 39 EXAMPLE: Zeroth Maps ................................................................................................. 39 Tasks and Flow..................................................................................................................... 40 Some Process Mapping Symbols ...................................................................................... 41 EXAMPLE: Tasks and Flows ........................................................................................... 42 Data...................................................................................................................................... 44 Basic Advice for Current State Data Collection................................................................. 45 METRICS: Task Data....................................................................................................... 46 EXAMPLE: Data Collection............................................................................................. 47 Evaluation of Value .............................................................................................................. 49 EXAMPLE: Evaluation of Value...................................................................................... 50 Understanding Iteration: the DSM ........................................................................................ 52 EXAMPLE: a DSM.......................................................................................................... 53 Summary .............................................................................................................................. 55 5.0 IDENTIFYING WASTE .................................................................................................... 57 The Info-Wastes ................................................................................................................... 57 2005 Massachusetts Institute of Technology 5 6.0 IMPROVING THE PROCESS ........................................................................................... 61 Establish a Takt Time ........................................................................................................... 62 EXAMPLE....................................................................................................................... 63 Assure the Availability of Information.................................................................................. 63 EXAMPLE....................................................................................................................... 64 Balance the Line................................................................................................................... 65 EXAMPLE....................................................................................................................... 66 Eliminate Unnecessary or Inefficient Reviews and Approvals............................................... 66 EXAMPLE....................................................................................................................... 67 Break Down Monuments ...................................................................................................... 68 EXAMPLE....................................................................................................................... 69 Eliminate Unnecessary Motion ............................................................................................. 69 Eliminate Unnecessary Documents and (Re-) Formatting ..................................................... 70 EXAMPLE....................................................................................................................... 70 Eliminate Unnecessary Analyses, Exploit Underutilized Analyses ........................................ 71 The Future State Map ........................................................................................................... 71 EXAMPLE....................................................................................................................... 72 Summary .............................................................................................................................. 74 7.0 BEYOND THE FUTURE STATE...................................................................................... 75 The LEM.............................................................................................................................. 75 LEM Overarching Practices (OAPs) ................................................................................. 76 Millard’s Value Stream Analysis Heuristics.........................................................................