VSM Example

VSM Example

Problem Statement

Create a VSM for the sub-assembly process with the following details given in the attachment.

How to perform analysis

Step 1: Open Sigma Magic
  1. Click on the Sigma Magic button on the Excel toolbar.
  2. Click on the New button to create a new project.

Step 2: Data Preparation
  1. Open the VSM.xlsx attachment
  2. Click on the Tool Wizard to add the analysis template.
  3. Click on Lean and then VSM.


Step3:
Click on Analysis Setup and specify the number columns, column width, VSM symbols and number paths. You can accept the default values for the given example.



Click on the Units and specify them.



Click on Create the worksheet will be created. Then create value stream map by clicking Manufacturing VSM symbols.
To create VSM you should use the symbols provided in Manufacturing VSM.
First click Customer Data icon on the top menubar to add icon to your worksheetand then click on the worksheet where you want the icon need to be placed. The following dialog box will opened where you can specify the customer details.


Notes
Note that Demand is required value and should be greater than zero.

If you want Supplier Data, click on Supplier Data



In the same way there are:
  1. Process Data
  2. Inventory Data
  3. Material Flow Data
  4. Information Flow Data
  5. Transport Data
  6. Staff Data
  7. Kaizen Data
You can add paths by clicking Define Path in the VSM symbols, click on the Add button and then click icons in the worksheet in sequence and then click on Cancel button to add the path.



Notes
If you make a mistake selecting the icons on the worksheet or if the icons have been changed you can Delete All to remove the entire path. If you want to delete specific icon, you can select the icon in the list and then Delete.
You can create ladder diagram by clicking on the Update Lader.
Once you have defined all the data and required paths foe analysis, verify the maps that you have created.


Step4:
If you need to make changes to the charts, click on the Analysis Setup and then the Charts tab. You can specify the following details,

 Labels:

  • Add a title for the chart.
  • Label the X-axis and Y-axis appropriately.

Appearance:

  • Adjust colors, font sizes, or other visual elements as needed.
  • Enable/disable gridlines or background shading.



Finally, click the Verify tab to ensure all the inputs are okay and shown in a green checkmark.



Click on Ok to close the dialog box.

Interpreting Results

The following conclusion can be drawn from this analysis.
​
Cycle Time vs. TAKT Time:
The Sub-assembly and Assembly processes exceed TAKT time, indicating bottlenecks and delays.
Shipment is well within TAKT time, reflecting efficient operation in this stage.

Lead Time Chart:
Lead time is significantly longer compared to the TAKT time, suggesting opportunities for improvement in reducing waiting times and process inefficiencies.

Process Flow Observations:
Material flow involves multiple stages with some delays.
Inventory accumulation may be contributing to extended lead times.

Actionable Insights:
Sub-assembly and Assembly processes should be streamlined to TAKT time.
Lead time should be minimized through the elimination of non-value-adding activities and optimization of material flow.

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