Note: This class is based on the book "Creating Mixed Model Value Streams" by Kevin J. Duggan, published by Productivity Press.

Advance from stable demand and low product variety into a world of complexity with a variety of products, variable demand, different cycle times, and shared resources.  This workshop takes the concepts of value stream mapping to the next level by showing you how to apply lean principles in a high-variety environment.  The case example begins with an existing current state map of a complex production environment, then shows you step-by-step how to develop the future state from such complexity.

In this workshop we will introduce product family selection in complex environments. From there we will learn how to create a value stream of multiple products flow at the pull of the customer. These concepts include:

• Determining true product families
• Creating continuous flow in a mixed-model environment
• Calculating takt time for a mix of products
• Determining equipment based EPEI at the pacemaker
• Creating standard work for a mix of products with varying cycle times
• Setting up first-in/first-out (FIFO) lanes
• Developing pitch and scheduling the pacemaker
• Leveling the schedule with Mix Logic Charts

"This class was right on the mark!"

"This class is should be called real life manufacturing!"

"Our company is much more complicated than the ACME Stamping Company. Now we know what to do!"

"Our instructor was great! Very knowledgeable and practical!"

"I can’t wait to get the book!"

 Program Agenda

The facilitator spends a total of 2.5 days at the host company.  The first half-day is for preparation with the company's team, and the second and third days are spent with the participants facilitating the workshop.

Day One 

On the day before class starts, the trainer and key sponsor members from the local team make preparations to ensure a rewarding experience for the students.

• Tour the work area to become familiar with the lean activities being performed.
• Review the present Value Stream Maps and product families
• Review the data collected by the host company prior to the session.
• Prepare data sheets for the class for their practical exercises.
• Review the class participant list and divide the students into mapping teams.
• Prepare the classroom for the session the next day.
• Brief senior managers about the training, and implement the appropriate advance communications in the host facility.

• Introduction
• Quick review of Value Stream Mapping
• Where ACME example left off (2 products, same cycle time, steady demand)
• Determining product families
• Determining shared resources

Using the data sheets provided (developed during the prep day) fill in the process map and determine the product families

• Takt time by family
• Equipment needed to support takt
• EPEI

Exercise 2 : Determine the interval, calculate takt time and resources for the product family

• Balancing processes to Takt time for the mix of products
• Creating standard work for the mix
• Developing Pitch for Mixed Model
• Leveling the mix for each interval

Exercise 3 : Create pitch and leveling for the product family

• Work with team on developing true product families
• Determining takt and equipment needs for their families
• Determining the intervals for the families
• Balancing the mix of products for flow
• Creating Pitch for the families
• Determining how to level production for the product families
• Handling changing customer demand
• Workshop conclusion