All resources

Manufacturing Efficiency through Continuous Value Stream Management

Value Stream Management
Posted by Yvonne Therese Mertens

Achieving Full Visibility of Value Streams

To achieve excellence in Lean Manufacturing, gaining complete transparency into current production and logistics processes is imperative. Value Stream Mapping, as part of Value Stream Management, is the initial stride towards visualizing the present state of information and material flows in manufacturing. This analysis helps to identify inefficiencies systematically which are eliminated in subsequent Value Stream Management stages.

Automated Value Stream Mapping through Industrial Process Mining 

ONIQ’s Industrial Process Mining technology harnesses log files from IT systems like MES, ERP, and PDA to automatically create visibility of process and material flows in manufacturing and supply chain. This technology gives rise to digital twins of value streams, offering a precise portrayal of actual production processes and material flows. These value stream twins encompass all vital data pertaining to process performance, including process times, output quantities, quality metrics, and energy consumption. 

The automated mapping and visualization of value streams revolutionizes the traditional manual data collection and documentation of value streams, which can often be time-consuming and error-prone. The digital value stream twin reduces the effort for Value Stream Mapping by 90%. With this technology, valuable working hours are freed up that were previously spent on manually collecting and analyzing value stream data. By eliminating sources of errors in manual data collection and analysis, the accuracy and reliability of Value Stream Mapping are significantly enhanced, leading to more substantiated decision-making.

Automated Value Stream Mapping stands out for its capability to visualize and analyze all value streams within a company, whereas manual Value Stream Mapping often focuses on a limited subset. This advantage of automation results from the ability to process all digitally captured production data, thus encompassing the entire manufacturing and logistics processes. Improvements to the value streams can therefore be analyzed and implemented across the entire value chain when a digital value stream twin is utilized.

Elevating Value Stream Improvement with Digital Lean 

Built upon the foundation of automated Value Stream Mapping, Value Stream Design empowers the creation of the desired state of operations. The value stream twin facilitates this stage, harnessing the value stream data for Digital Lean analysis. 

Digital Lean integrates digital technologies like automation, data analytics, and AI into Lean Manufacturing, optimizing processes for increased efficiency and reduced waste.

Through these targeted analyses, pain points such as excessive WIP inventory, bottlenecks, and deviations from work plans are pinpointed in the value streams. Specialized root cause analyses additionally employ AI techniques to identify the primary sources of these pain points swiftly and data-driven. This paves the way for rapid and data-backed discovery of optimization opportunities in all Manufacturing value streams of a company.

Ensuring Adherence to Enhanced Processes

In the next step Value Stream Planning focuses on comprehensive planning, implementation, and continuous monitoring of improvements to the value streams. A key advantage of automated Value Stream Mapping is its ability to integrate historical and current value stream data, creating an always up to date value stream twin. 

This enables the assessment of the current performance of value streams and facilitates the identification of trends and developments over time. Continuous benchmarking plays a pivotal role in monitoring the effectiveness of improvement measures, as the digital twin constantly compares actual and target value streams. Any deviations and gradual deteriorations can thereby be promptly detected and addressed. The availability of real-time value stream data further presents the opportunity for an immediate response to unforeseen events or production deviations, thereby bolstering adaptability in an ever-evolving production environment.

In conclusion, continuous benchmarking and Digital Lean analyses enable companies to develop long-term optimization strategies and to continuously monitor improvements in their value streams.

Data-Driven Decision Support for Lean Manufacturing

Software-enabled continuous Value Stream Management provides comprehensive visibility into actual production and logistics processes. Decisions aimed at streamlining the value stream are rooted in extensive and detailed process data, encompassing all facets of process performance. Leveraging Industrial Process Mining and AI, complex relationships within the value streams are automatically detected. Production and logistics managers can continuously optimize processes, enhancing production efficiency and sustainability with the digital value stream twin. 

The digital value stream twin accelerates and refines Value Stream Management, serving as a cornerstone for digital Lean Manufacturing in the era of Industry 4.0.

Bring Light into Your Manufacturing Processes