KTSMIFADiagramsQuickReferenceTITLE•Focusonfullyunderstandingtheflowofoneproduct,serviceorprocessvaluestream.•ResistthetemptationtoleaptoafuturestatebeforeunderstandingthecurrentstateIMPLEMENTATION•ForafullexplanationseeKTPMIFADiagrams•FordoingtheM.I.F.Analysis,seeKTPFutureStateSystemsDesign,andKTSFutureStateQuickReferenceRELATEDTOPICSTwoStagesofMIFA1KeyPoints2StandardSymbols3SevenStepstodrawanyMIFADiagram4HOW?-DiagnosticMaterialandInformationFlowAnalysisisusedtorevealthesourcesofwasteinthecurrentstate,andtodesignandcommunicatetheimprovedvision©McKinsey&CompanyInc.2002PROCEDURE/EXPLANATION/STAGESorCALCULATIONPURPOSE•Thereare3typesofflowinabusiness:Material,InformationandPeople&Processinteractions•MIFAconsidersthewholevaluestream,notjustonepartofit(People&Processoptimisation)•AMIFAdiagramisononesheet,inastandardformatUpdated28/08/2002byKBaManagerBMcCurrentStateDiagramFutureStateDiagramRigorousfactbasedanalysisCreativedesignsynthesisCurrentFuture‘Firstin–firstout’sequenceFIFOPullarrow(Physicalpullifnokanbansshown)MovementofgoodstofromsupplierandtocustomerPusharrowShopstockOutsidesourceCOMPANYNAMEDataboxWithexamplesofdataC/T=C/O=Shifts=Uncontrolledinventory(of3000units)3000Lorrymovement1perweek250perboxASSEMBLYManufacturingProcessInventorycontrolledbylocation,quantityandreplenishmentmethodDocument(exampleshowsmanualdistribution)PartswithdrawalkanbanProductioninstructionkanbanSignalKanbanLevellingboardKanbanpostElectronicinfoflowManualinfoflowPIPWTabletkanbanTIdea/ProblemMATERIALSYMBOLS:INFORMATIONSYMBOLS:1.DefineCustomerRequirements-Drawincustomer,andcustomerdatabox,eg:•Quantitiesoforderspervariant•Ordersize(min,max,avg.)•Packagingsize•Shipmentschedules•Customerleadtime•Orderadjustments-Drawincompanyandrelevantdepartmentsforinformationflow-Drawinmainsupplier(s),anddatabox2.DrawProcessSteps,separatedbyinventory-AProcessisNOTthesameasadepartmentorfunction-Aprocessisanactivitywherematerialcanstagnateeitherside-Parallelprocessesaretobedrawnaboveeachother-Aboxcanbedrawnaroundprocessesinthedepartment-Todistinguishstationsonaline,usemultipledataboxes3.GatherProcessData-Eg.-Availabletime(Scheduledtime-managementallowances)-Machineandmanualcycletimes-Machinereliability-Batchsize,Changeovertime-Sharedordedicatedprocess(withothervaluestreams)?-Numberofoperators-Shipmentquantitiesandtiming(supplierandfinishedgoods)-Scraprate4.GatherInventoryData-usebellcurveifinventoryisnotcontrolled-useaseparatebellcurveforeachlocation,indicateasnapshotoftotalunitsstored(separatecountsofeachvariant)-controlledinventoryiseitherFIFOorshopstock-Standard-In-ProcessStock(SIPS)isnotusuallyshownonaMIFAdiagram-seenoteopposite•Don’tworryaboutstructureonthefirstdraft–justdraw(orusestick-its)ontheprocessesandorganisethem(steps1&2),thendosteps37.•‘GenchiGenbutsu’–‘Go&See’,don’tjustbelievewhatyou’retold.Peopletendtobeoptimistic,andtoguessiftheydon’tknow,sotryandmeasureeverythingforyourself.WeeklyDemand:2000A1000B4000CWeeklyDemand:500palletsSuppliersCustomersCompanySalesOrdersPurchaseOrders1WeeklyDemand:2000A1000B4000CWeeklyDemand:500palletsSchaublinSaw&DeburrWeld&De-carbRotajetPaint‘G’Build,&TestDispatchSuppliersCustomersCompanySalesOrdersPurchaseOrders2WeeklyDemand:2000A1000B4000CWeeklyDemand:500palletsSchaublinAvailabletimemanualcycletimemachinecycletimemachinereliabilitychangeov...
