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

This book describes in detail how to create a complete Value Stream Map for a process industry manufacturing operation. Describing the unique features of process operations and why they require additions and adjustments to traditional VSMs, the book describes an actual process operation and uses it to describe in detail how to create the VSM. It defines all of the terms required for process VSM data boxes and uses the example process to illustrate all of the calculations required.

Jennifer S. King is an operations research analyst with MCR LLC, analyzing operational impacts of emerging FAA technologies and developing cost and performance models to support airline investment decisions. Prior to that, she spent five years with the Department of Defense developing discrete event simulation models to assist the army in setting reliability requirements for new platforms, and analyzing performance of weapon systems alternatives. Her prior publishing experience includes editing textbooks and developing mathematics problems and solutions for ExploreLearning. She is the co-author ofThe Product Wheel Handbook—Creating Balanced Flow in High Mix Process Operations(Productivity Press, 2013).

Jennifer has degrees in Mathematics and Psychology from the University of Virginia, and a master’s degree in Operations Research from the University of Delaware. She is a member of INFORMS.

Peter L. King is the president of Lean Dynamics, LLC, a manufacturing improvement consulting firm located in Newark, Delaware. Prior to founding Lean Dynamics, Pete spent 42 years with the DuPont Company, in a variety of control systems, manufacturing systems engineering, Continuous Flow Manufacturing, and Lean Manufacturing assignments. That included 18 years applying Lean Manufacturing techniques to a wide variety of products, including sheet goods like DuPont? Tyvek^R, Sontara^R, and Mylar^R; fibers such as nylon, Dacron^R, Lycra^R, and Kevlar^R; automotive paints; performance lubricants; bulk chemicals; adhesives; electronic circuit board substrates; and biological materials used in human surgery. On behalf of DuPont, Pete has consulted with key customers in the processed food and carpet industries. Pete retired from DuPont in 2007, leaving a position as Principal Consultant in the Lean Center of Competency. Recent clients have included producers of sheet goods, lubricants and fuel additives, vitamins and nutritional supplements, and polyethylene and polypropylene pellets.

Pete received a bachelor’s degree in Electrical Engineering from Virginia Tech, graduating with honors. He is Six Sigma Green Belt certified (DuPont, 2001), Lean Manufacturing certified (University of Michigan, 2002), and is a Certified Supply Chain Professional (APICS, 2010). He is a member of the Association for Manufacturing Excellence, APICS, and the Institute of Industrial Engineers.

He served as president of IIE’s Process Industry Division in 2009–2010. Pete is the author ofLean for the Process Industries—Dealing with Complexity (Productivity Press, 2009), and several published articles on the application of Lean concepts to process operations. He is the co-author ofThe Product Wheel Handbook—Creating Balanced Flow in High Mix Process Operations(Productivity Press, 2013). He has been an invited speaker at several professional conferences and meetings. He has presented seminars and taught courses across the globe on the application of Lean concepts to process operations.