From Value Stream to Measured Step

Whether in production, administration or IT, a value stream in the LeanShift App is made up of tiles such as processing, storage, transport, inspection or setup. You attach a recording to a tile, and every step in it is timed individually over several cycles. The tile then uses the measured time.

Production

Screw manufacturing from wire coil to packaging

The value stream follows a production order for screws from wire coil to packaging, tile by tile. A tile with a recording takes its actual time from that recording, averaged per step and added up. In setup, the steps marked as external in this example also count toward the tile’s changeover time. Subtract the time of these steps by hand in the “Changeover Time (C/O)” field. In thread rolling, one cycle runs from one bin to the next, so the tile takes the time for a whole bin and not for one screw.

from the Expert version

Value stream Flow of a production order

Plant manager

  1. StorageCoils of wire in storage
  2. TransportCoil of wire to the cold header
  3. Setup / ChangeoverCold header setup
  4. ProcessingCold heading (head and shank)
  5. TransportBlanks to the thread rolling machine
  6. Wait TimeBlanks waiting for thread rolling
  7. Setup / ChangeoverThread rolling machine setupwith recording
  8. ProcessingThread rollingwith recording
  9. TransportScrews to heat treatment
  10. Wait TimeScrews waiting for heat treatment
  11. ProcessingQuench and temper
  12. TransportScrews to zinc plating
  13. Wait TimeScrews waiting for zinc plating
  14. ProcessingZinc electroplating
  15. TransportScrews to visual and dimensional inspection
  16. Wait TimeScrews waiting for visual and dimensional inspection
  17. InspectionVisual and dimensional inspection
  18. ProcessingCounting and packing
from the Operator version

Recording Thread rolling machine setup

Setup technician

  1. 1.Stage new flat dies, hand tools, thread ring gauge and micrometer at the machineexternal in this example
  2. 2.Stage blanks for the next job at the machineexternal in this example
  3. 3.Stop the machine and remove leftover blanks from hopper and feed rail
  4. 4.Open the guard
  5. 5.Loosen and remove the old dies
  6. 6.Insert and clamp the new stationary and moving flat dies
  7. 7.Load blanks for the next job into the hopper
  8. 8.Adjust feed rail and injector to the new blank
  9. 9.Set die gap and parallelism and adjust die match
  10. 10.Close the guard
  11. 11.Roll test pieces
  12. 12.Check test pieces with a go/no-go thread ring gauge and measure the major diameter
  13. 13.Release the machine for production
  14. 14.Clean the old dies and return them to the tool storeexternal in this example

The SMED method divides a setup into external steps, which can be done before or after the changeover while the machine is producing, and internal steps, which can only be done while it is not producing. The aim is to convert internal steps into external ones and to streamline all the rest. The recording shows you how long each step takes. You decide at your own machine whether a step is internal or external.

from the Operator version

Recording Thread rolling

Machine operator

  1. 1.Load blanks into the hopper
  2. 2.Injector feeds blanks between the flat dies, and rolled screws drop into the bin
  3. 3.Take a sample from the bin
  4. 4.Check the external thread with a go/no-go thread ring gauge
  5. 5.Swap the full bin for an empty one

Administration

Order processing from customer inquiry to invoice

The department head sets up order processing as a value stream, from customer inquiry to invoice. The cost estimator’s recording is linked to the “Prepare quote” tile, with every step of preparing the quote timed on its own. The tile takes its actual time from that recording, averaged per step and added up.

from the Expert version

Value stream Order processing

Department head

  1. ProcessingLog and assign customer inquiry
  2. Wait TimeInquiry waits for quote preparation
  3. ProcessingPrepare quotewith recording
  4. Wait TimeQuote waits for approval
  5. InspectionReview and approve quote
  6. TransportSend quote to customer
  7. InspectionCheck incoming purchase order against quote
  8. ProcessingCreate sales order
  9. TransportSend order confirmation to customer
  10. ProcessingCreate production order
  11. ProcessingOrder material
  12. Wait TimeOrder waits for material
  13. InspectionCheck and post goods receipt
  14. Wait TimeOrder waits for production
  15. ProcessingManufacture parts
  16. ProcessingCreate delivery note
  17. TransportShip goods to customer
  18. ProcessingCreate invoice
  19. TransportSend invoice to customer
from the Operator version

Recording Prepare quote

Cost estimator

  1. 1.Review inquiry and drawing (quantity, material, delivery date)
  2. 2.Derive bill of materials and operations from the drawing
  3. 3.Determine direct material costs from quantity required and material price
  4. 4.Apply material overhead rate
  5. 5.Estimate setup time (once per batch) and run time per piece separately for each operation
  6. 6.Calculate machine costs using machine hour rates
  7. 7.Calculate direct labor costs and apply a labor-based rate for the remaining production overhead
  8. 8.Add outside processing costs from supplier prices
  9. 9.Apply sales and administration overhead rates to cost of goods manufactured
  10. 10.Add profit markup on total cost
  11. 11.Build in customer cash discount and trade discount, set the quote price
  12. 12.Enter quote with delivery time and payment terms in ERP
  13. 13.Submit quote for approval

IT

Software release from backlog to production

The IT manager looks at the value stream of a release from backlog to production. Linked to the “Run production deployment” tile is the DevOps lead's recording, with every step timed individually, from the deployment checklist to the check in production. The tile takes its actual time from these steps.

from the Expert version

Value stream Release cycle

IT manager

  1. ProcessingSelect release tickets from backlog
  2. ProcessingImplement tickets in the sprint
  3. InspectionSprint review with stakeholders
  4. ProcessingCompile release notes
  5. InspectionQA tests in test environment and signs off
  6. ProcessingUpdate staging environment
  7. Wait TimeWait for acceptance testing
  8. InspectionBusiness users run acceptance tests (UAT) on staging
  9. InspectionMake go/no-go decision
  10. Wait TimeWait for maintenance window
  11. ProcessingRun production deploymentwith recording
  12. TransportSend release email to stakeholders
from the Operator version

Recording Run production deployment

DevOps lead

  1. 1.Open deployment checklist
  2. 2.Pull new image
  3. 3.Review pending database migrations
  4. 4.Activate maintenance page and stop application containers
  5. 5.Start production database backup
  6. 6.Wait for backup to complete
  7. 7.Run pending migrations from new image
  8. 8.Recreate containers from new image
  9. 9.Call health check endpoint
  10. 10.Run smoke tests
  11. 11.Deactivate maintenance page
  12. 12.Check application in production

Ready for better processes?

The simple stopwatch is free. Recording your own processes step by step is available from the Operator version. The value stream map, the target state calculator and the investment calculator are available from the Expert version.

Discover the App