ABSTRACT
The objective of this chapter is to demonstrate a product’s journey from sales order through to customer delivery for Overall Process Time and Overall Lead Time. Current State Map: the AS IS map identifying all process times and all WIP in terms of Inventory/Delays. At the end of the map, a Total Cycle Time and Total Lead Time will be established. Also conduct a doctor’s surgery with local experts for the 3Cs: Concern, Cause, and Countermeasure, and carry out a Spaghetti Diagram on product travel distances. Future State Map: the Potential for Improvement. Target to reduce WIP, Overall Lead Time, and Distance of travel. Also apply any Countermeasures from the 3Cs. I have conducted six Top Level VSMs over three industries: automotive, aerospace, and oil and gas. The first was at a traditional foundry on a small casting. Current State Overall Lead Time was 93 days and 2.1 miles of internal travel – Future State Lead Time was reduced to 42 days. Actual realised was 64 days and travel reduced to 0.5 miles.
