CreateASoft, Inc.
The Process Improvement Company

Analyzing complex value streams with Simulation


Hosni Adra
Product Manager/Partner

Outline
 

• Introduction
• Value stream maps – Benefits and overview
• Simplifying the complex VSM.
• VSM Analysis.
• Application and examples.
• Q&A
   

About CreateASoft, Inc.

• In business since 1992
• Core technology: Simcad Process Simulator software
• Provides Simulation and Process Improvement services to the manufacturing and service industries in the areas of
• Automation, manufacturing, and process improvement.
• Lean transition and implementation.
   

Simcad Process Simulator

• Discrete-Event based process simulator with extended continuous simulation capabilities.
• Design and developed in the US by CreateASoft, Inc.
• Currently used by many companies,
  • Jostens, Baxter, USAF, Bechtel SAIC, The US Department of Energy, Rumble Automation, LaSalle Bank, Florida hospital, Gambro BCT, and many others..

What is Lean?

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Common issues

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Key to Lean success

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The Value Stream Map

• Process flow
• Displays flow characteristics
  • Process constraints and performance.
  • Timeline – Helps identify total waste time. 
• Help in identifying the critical path.
• Good documentation tool.

Issues with VSM

• Has a tendency to grow too large
  • Many value streams span multiple “walls”
• Contains “static data”
  • How does the value stream change when the process flow or product mix changes.
  • Impact on the rest of the value stream (Up stream and down stream).
• Good for static environment, but can be challenging otherwise.
  
  
  
   

Simplifying the VSM

• VSM can be simplified through the use of layers.
  • Patented technology developed by CreateASoft*.
  • Allows the value stream to be viewed at varying levels of detail.
    • One Stream can act as the supplier or consumer to one or more streams.
    • Each Layer can be represented as a single process or a collection of processes.
• Enhances the visibility and representation of the VSM.
• Forces the interaction requirement between multiple VSMs.  

Example of a VSM Layers

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A VSM Layer

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The Role of Dynamic VSM

• Issues facing the Job shop:
  • Routing will vary per Job.
  • Job Mix varies constantly.
  • Resource allocation issues.
  • Lead time control – When can we deliver ?
• Dynamic VSM updates the contents of the VSM based on the input constraints, without user interaction.

Impact on the Big Picture
 

• By allowing the VSM to be dynamic, flow constraints and routing changes have a direct impact on results.
• Lead times, VAT, waste time are automatically identified.
• “Critical path” is computed.
• Interactions between multiple streams is simulated, with problems dynamically identified.
• Faster Results, better control over the operation.

Dynamic Behavior

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Connectivity

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D-VSM and Complex streams

• Complex and layered Value stream are harder to control and track.
  • How does one change impact the big picture?
• The effect of a 6 Sigma implementation that improves one stream can create problems in others down stream.
• The task can be delegated to others
• Improves information flow.
• Takes into consideration the “time” factor.
  

Example of a complex VSM
 

• Each subassembly, and department is identified in its own VSM.
• Smaller VSMs can be analyzed separately or as part of the big picture.
• Impact of change analyzed.
• Determining the Critical path based on current constraints.
• Impact of the equipment location on efficiency and lead time.
• Example (A Sample Job Shop )
  
  

CreateASoft, Inc.
The Process Improvement Company

Analyzing complex value
streams with Simulation

Q & A