Value Stream Mapping for the Process Industries : Creating a Roadmap for Lean Transformation

Providing a framework that highlights waste and its negative effects on process performance, value stream maps (VSMs) are essential components for successful Lean initiatives. While the conventional VSM format has the basic structure to effectively describe process operations, it must be adapted and expanded to serve its purpose in the process industry.This book describes in detail how to create a complete VSM for a process industry manufacturing operation. Detailing the unique features of process operations and why they require additions and adjustments to traditional VSMs, the book walks readers through the steps in analyzing the map. It explains how to scope improvement projects, prioritize them, and then use future state VSMs to illustrate and motivate systemic improvement. In doing so, it supplies readers with a roadmap for a complete Lean transformation.Describes how to analyze the map for waste and flow issues so that they can be reduced and even eliminatedProvides examples of the calculations needed for the flow parameters in data boxesExplains how the VSM concept can be applied to the entire supply chainIncludes strategies for engaging your entire workforce in map creationThe book introduces a target manufacturing process and uses it to describe how to create a complete VSM. The target process is complex enough to illustrate the issues often encountered in mapping a process industry operation, but straightforward enough to explain all of the mapping considerations and decisions.The book includes real examples of how VSMs brought much greater clarity to the real issues the processes faced and cases where the insight enabled management to avoid costly, inappropriate investments.

Clearly, concisely, and with many examples from public and private enterprise, Upgrading Leadership‘s Crystal Ball shows why predictions are usually wrong and presents a better way to look at the future forecasting. This book is essential-reading for anyone who needs to make the best possible strategic decisions for moving an organization forward in today‘s rapidly changing environment.Dr. Bauer supplies an insightful comparison of the two mainstream approaches for looking ahead. Although predicting and forecasting are usually used as synonyms for a single process, they are conceptually and methodologically quite different. He explains why everyday failure to operationalize these differences robs us of power to envision and pursue good futures, especially when we are headed in the wrong direction. Readers will learn the real-world value of distinguishing between predicting (extrapolating historical trends) and forecasting (estimating the probabilities of possibilities). Following a description of predictive modeling and a discussion of five reasons why it fails so often in current applications, Dr. Bauer explains the superiority of forecasting and how to do it. To complete readers understanding of the many compelling reasons for making the shift from predicting to forecasting, Upgrading Leadership‘s Crystal Ball presents a practical approach to strategic planning in unpredictable times. It concludes with an analysis of the future of big data and its likely impact on the future.Dr. Bauer is uniquely qualified to write this important book; he is trained in both predicting (economics) and forecasting (meteorology). Author of more than 250 publications, he is internationally recognized not only for long-term success in foretelling the future of medical science and health care, but also for successful innovations to create a better delivery system. This book distills the lessons garnered over his 40 ye