Applying Value Stream Mapping (VSM) Tool to Improve Annual Plant ...

Applying Value Stream Mapping (VSM)
Tool to Improve Annual Plant Aerosol
Mapping Process
Maria Pryor
Sr. Industrial Hygienist
General Motors

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What Is Aerosol -
and Why do we Care?
Metal Removal Fluids (MRFs) are used as coolants and/or cutting oils
MRF Aerosols are generated during the machining process
High levels of MRF Aerosol are associated with lung function changes
and increased risk of asthma. Exposure to mist is also associated
with hypersensitivity pneumonitis, a serious lung disease.
OSHA has set a Permissible Exposure Limit for MRF Aerosol is 5
mg/m3, based on eight hours of worker exposure.
The GM Occupational Exposure Guideline is 1 mg/m3.
GM Powertrain Specifications call for new equipment to meet 0.5
t to meet 0.5
mg/m3.
GM and the UAW have done a lot of work to reduce MRF Aerosol.

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What is an Aerosol Map?
It’s a tool, and a picture.
MRF Aerosol levels are
overlayed onto a plant
layout.
It doesn’t tell you who is
overexposed.
It does show you where the
“hot spots” are, and where
to focus engineering efforts
to improve. It can also show
year-to-year changes.

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Why Improve the Current Process?
Long lead time for aerosol map
Too many hand-offs for report creation
Timing of report and map delivery
asynchronous
Need more standardized elements in process
Need to reduce resources required
Need to improve logistics

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Value Stream Map (VSM) Tool
A Value Stream Map (VSM) involves all the
steps, both value added and non-value
added, required to complete a product or
service from beginning to end.
It makes the process more visual in order to
identify hidden wastes.
It shows bottlenecks, rework or waiting that
affect the flow of the product or service.

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VSM Team
Leadership Panel
Director, Chemical Risk Management
Manager, Industrial Hygiene & Toxicology
Manager, Industrial Hygiene
Sr. Manager, Health & Safety
Manager, Divisional Health & Safety
Research & Development
Workshop Participants
Sr. Industrial Hygienist
Sr. Industrial Hygienist
Sr. Industrial Hygienist
Sr. Industrial Hygienist
Research Engineer
GMS Coaches
Coaches in Training
Coach:

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Purpose Statement
Project Description
To improve the efficiency of GM’s plant aerosol source mapping
process
Project Objectives
•
Aid GM’s efforts to reduce worker exposure to MRF aerosols
•
Reduce resources required for mapping
•
Improve quality of deliverables (map & report)
•
Reduce lead time
•
Reduce associated costs
•
Improve map production & data collection
•
Aid GM’s efforts to prevent pollution at source

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Aerosol Mapping Process Current State Map
UAW
Research &
WFG ES Chem. Mgmt. Industrial Hygiene
Development
Yearly
Maintain
NJC,
Schedule
Yearly
Lead
Research
Yearly
& Update
Div. Board
Schedule
Schedule
I.H.
Engineer
Yearly
Aerosol Mapping
Schedule
Deliverables
Team
Aerosol Maps
Plant
• Aerosol Map
Database
I.H.T.
Data
Plant
• Yearly data comparison
Sheets
• Mapping Report
• PSRB Presentation
Data
Sheets
Data
Sheets
PE, ME
Data
Sheets
Yearly Aerosol
Plant
Mapping Review
Day of Mapping
IE/PE
WFG
Calibrate
Pool data
Central
instruments
sheets
Layout
Communicate
Secure
with Team
instruments
Request Plant layout CAD
Iterati
Iterati
Iterati
Iterati
on
on
on
on
I
I
I
I
I
I
I
Secure Plant
Decide Sample
Prepare Mapping
Data Entry
Data
Set up Plant
Add Dummy
Export data to
Map Production
Final Map Print
Layout CAD
Collect
Points
Handouts
2
into Excel
0
0
Processing
Grid
0
Points
0
DeltaGraph
0
in DeltaGraph
0
& Ship
Aerosol Data
1-3
1
1
1
1
1
1
1
1
1
1-9
P/T = 1-5 days
P/T = 1 day
P/T =1 day
P/T = 1-3 days
P/T =2 days
P/T =0.5 day
P/T =0.25 day
P/T =0.5 day
P/T =5 min
P/T =0.5 day
P/T =1 day
FTQ = 75%
FTQ = 90%
FTQ = 85%
FTQ = 70%
FTQ = 90%
FTQ = 90%
FTQ = 95%
FTQ = 90%
FTQ = 99%
FTQ = 90%
FTQ = 90%
1-5 days
1 day
1 day
1 – 3 days
2 days
0.5 day
0.25 day
0.5 days
5 min
0.5 day
1 day
0
0
0-2 days
5 days
0
0
0
0
0
0
3 days
Iterati
on
I
I
Type
Pool Obs. &
Send Obs.
I
Ship
Legend
Observations
Make Report
0
To Lead I.H.
0
Report
Icon
Interpretation
P/T Value added process time
1-9
1
1-9
1
FTQ First Time Quality
Iterati
Iterative work
on
P/T = 60 min
P/T =10 min
P/T = 1 day
P/T = 30 min
# of operators
Total lead time
30 days
Prepared by
FTQ = 90%
FTQ = 99%
FTQ = 90%
FTQ = 99%
Net cycle time
15 days
Inventory
I
Sid Kinare, Sandeep Pavnaskar
Net value added time
6 days
Work document generated
Aerosol Map VSM Team:
60 min
10 min
1 day
30 min
6 days
Jim D’Arcy, Jim Griffin, Dave Thorpe
Value added ratio
20%
Two way information flow
Maria Pryor, Bob Chapman, Graham Parr
1-10 days
0
0
3 days
One way information flow
August 10, 2004
FTQ
22.30447%
One way information fl

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In scope
Out of scope
Develop Master schedule for
Develop an electronic data
contract period
collection system
Standardize data collection
Pilot electronic data collection
sheets for all plants
Automate the mapping report
Standardization of report
elements
Secure funding for
continuous improvements
Reduce data collection runs
for non-production areas
Annual aerosol maps report
Develop “aerosol mapper”
Data analysis and statistics
training module
Migration of historical aerosol
Identify and increase qualified
maps into software
“mapper” pool
Pilot aerosol map production
& deployment using software

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Aerosol Mapping Process Future State Map
Trigger –
yearly schedule
Checkpoint
PT IE
WFG - IH
Central Layout
1
I
I
I
Prework &
Collect
Pool data into
Input data &
Generate
Deliver 1 CD
Email reminder
Secure yearly
Deliverables
Review
Aerosol Data
Template;
0
comments;
0
0
Report
to Plant
Plant
of current year’s
updated Plant
Email to R&D
• Aerosol Map
Email to IH
IHT
mapping
Layout CAD
Plant
• Mapping Report
schedule
(late April)
- Std. Plant
- DustTrak
- Std. Plant
- Std. Plant
- Std. Report
- ArceRader
Template
1-2
-Paper
1-9
Template
Template
1-9
1
Format
1
- PDF
1
(early January)
IH Manager
R&D
Lead IH, IHT
Mapper
Mapper
Lead IH
Lead IH
Lead IH
P/T = 1-3 days
P/T = N/A
P/T = N/A
P/T = 1 day
P/T = 1 day
P/T = 1 day
P/T = 1 day
P/T = 1 day
Mapping
Checkpoint
report
W/T = N/A
W/T = N/A
W/T = 0 days
W/T = 0 days
W/T = 0 days
W/T = 1 days
W/T = 0 days
2
W/T = 0 days
WFG – IH
FTQ = N/A
FTQ = N/A
FTQ = 100%
FTQ = 85%
FTQ = 95%
FTQ = 95%
FTQ = 90%
FTQ = 85%
Review next
year’s mapping
I
schedule and
Upload data
Ship 2 CD’s
Update
resources
into GIS
0
(map &
Metric Sheet;
(late November)
Map
report)
Email to IH
Template
to IH
Manager
- Excel
1
IH Manager
- Excel
1
- ArcGIS
1
P/T = 1 day
R&D
R&D
R&D
W/T = 0 days
P/T = 2 days
P/T = 3 days
P/T = 1 days
FTQ = 100%
W/T = 0 days
W/T = 0 days
W/T = 0 days
FTQ = 90%
FTQ = 100%
FTQ = 100%
Maintain
& Update
Legend
Icon
Interpretation
Continuous
Aerosol Maps
P/T Value added process time
Improvements
Database
W/T Wait time
First time quality
FTQ
# of operators
Total lead time
14 days
Prepared by
Inventory
I
Net cycle time
13 days
Sid Kinare, Robin Richey
Work document generated
Net value added time
13 days
Aerosol Map VSM Team:
Two way information flow
Value added ratio
57.14285%
Jim D’Arcy, Jim Griffin, Dave Thorpe
Maria Pryor, Bob Chapman, Graham Parr
One way information flow
FTQ
69.04125%
September 10, 2004

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