WO2014138271A2 - Cloud-based real-time value stream mapping system and method - Google Patents

Abstract

A web-based system and method of improving the efficiency of processes of all types that allows users to generate value stream maps with integrated key metrics that may be evaluated and automatically revised. The value stream mapping system and method generates reports that capture and display the key metrics in various meaningful formats, such as workflow lists, which the user may use to analyze a process and revise to improve the efficiency of a process. The system and method allows the user to toggle back and forth between a current state and a future state of the process in order to recalculate key metrics and determine a more efficient process.

Description

CLOUD-BASED REAL-TIME

VALUE STREAM MAPPING SYSTEM AND METHOD

INVENTORS

CINDY WHITEHEAD

&

PHILIP S . WY ATT

RELATED APPLICATIONS

[0001] This application claims priority of U.S. Provisional Application Serial No. 61/772,606, filed on March 5, 2013, entitled "INTEGRATED VALUE STREAM MAPPING AND AUTO- GENERATING LEAN METRICS," which application is hereby incorporated in its entirety by reference in this application.

BACKGROUND OF THE INVENTION

1. Field of the Invention.

[0002] The invention is related generally to practices and approaches designed to improve the efficiency of workplace manufacturing and business processes, and more particularly, to utilizing value stream mapping to identify waste and inefficiencies in all types of business processes.

2. Related Art.

[0003] Efforts at improving the efficiency of business processes generally began with manufacturing practices, one example being Henry Ford's mass assembly line manufacturing system. In the 1990s, lean manufacturing, or lean production, became the focus of attention, being a management philosophy primarily derived from the Toyota Production System (TPS), which was designed to eliminate various forms of waste from the automobile manufacturing process. Over time, other approaches and tools were developed, such as Six-Sigma, Design for Manufacture (DFM), just-in-time (JIT), Kaizen, poka-yoka (error-proofing), etc. Lean manufacturing eventually became known as Lean Metrics, or simply, "Lean."

[0004] Lean principles may also be applied to services, such as call center services and software application development and maintenance and other areas of information technology (ΓΓ). As an example, by standardizing processes and utilizing agent-controlled prerecorded audio files, a company reduced handle time and improved agent-by-agent and call-by-call performance. There has, however, been a problem in translating examples of Lean "approaches" or "tools" to the services sector because of the lack of widely-recognized reference implementations in this sector.

[0005] A tool widely used to identify waste in processes is value stream mapping (VSM). VSM is generally performed by inputting specific information into a mapping software application that graphically displays a process. One example of such software is Microsoft® Office Visio, which includes stencils for VSM and Six Sigma Diagrams. In general, the VSM tool calls for creating a current state diagram that shows how the process currently works. Next, problem areas of the process are identified, and then a future state diagram is created that pinpoints where the process could be changed to eliminate or reduce the waste.

[0006] Current VSM tools lack an ability to generate metrics to evaluate the maturity, cost, or Lean functionality of the steps of the process. Also, metrics are required to be captured manually and then analyzed by re-entering the information into a spreadsheet program, such as Microsoft® Excel. Several key VSM metrics are time-related and in general, process flow diagrams and traditional value maps lack entirely any of these time elements. This industry standard method is time consuming to implement and doesn't allow for the practitioner or user to quickly move from an inefficient "current state" process map to a new improved "future state" design that eliminates waste.

[0007] In view of the foregoing, there is an ongoing need for providing a software application with logic to automate the process of generating and analyzing VSM diagrams so as to allow a user to easily prepare the desired VSM graphics, recalculate key metrics, and generate the various reports.

SUMMARY

[0008] To address the foregoing problems, in whole or in part, and/or other problems that may have been observed by persons skilled in the art, the present disclosure provides systems, apparatus, instruments, devices, methods, and/or processes, as described by way of example in implementations set forth below.

[0009] A cloud-based (or web-based) value stream mapping (VSM) tool allowing users to directly input process steps or tasks into a cloud-based interface without the need for individually licensed process mapping software assigned to a specific energy storage device (or system) is disclosed. Using this VSM tool, the user may input key information or metrics that will be integrated into VSM current state and future state diagrams, and immediately generate reports in various graphical layouts. The user may also toggle back and forth between the "current state" and the "future state," modify or adjust key metrics, and then immediately generate VSM diagrams and reports reflecting the modifications and adjustments.

[0010] Because the VSM tool is cloud-based, multiple users will be able to establish accounts through an electronic request, thus allowing improvement practitioners to be in the same room with their clients, or to use web conferencing several countries apart. Users will be able to log out of the VSM tool without losing their work. When they log back on, they'll resume exactly where they left off. Each user can only view and access his or her own workflows, even if they have multiple people in their organization also using the VSM tool and mapping other processes.

[0011] Other devices, apparatus, systems, methods, features and advantages of the invention will be or will become apparent to one with skill in the art upon examination of the following figures and detailed description. It is intended that all such additional systems, methods, features and advantages be included within this description, be within the scope of the invention, and be protected by the accompanying claims.

BRIEF DESCRIPTION OF THE FIGURES

[0012] The invention may be better understood by referring to the following figures. The components in the figures are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention. In the figures, like reference numerals designate corresponding parts throughout the different views.

[0013] FIG. 1 shows an exemplary topology diagram of a cloud-based value stream mapping (VSM) approach for connecting numerous remote devices to a VSM tool in accordance with the invention;

[0014] FIG. 2 shows an example of an interface available to a user of a VSM tool in accordance with the invention;

[0015] FIG. 3 shows an example of a current state Workflow List generated by a VSM tool in accordance with the invention for the client listed in FIG. 2;

[0016] FIG. 4 shows an example of an interface available to the user to add steps to Workflow List of FIG. 3.

[0017] FIGs. 5A, 5B, and 5C show a current state Workflow Listing of an example value stream mapping generated by a VSM tool in accordance with the invention;

[0018] FIGs. 6A and 6B show a Metrics report of the Workflow Listing shown in FIGs. 5A, 5B, and 5C.

[0019] FIG. 7 shows a list of the Opportunities and Alerts contained in the Workflow Listing shown in FIGs. 5A, 5B, and 5C. [0020] FIGs. 8A and 8B show a future state Workflow List of the example value stream mapping generated by a VSM tool in accordance with the invention; and

[0021] FIG. 9 illustrates a flow diagram of a method of generating integrating video stream map comprising current state diagrams and future state diagrams in accordance with the invention.

DETAILED DESCRIPTION

[0022] An example approach for cloud-based value stream mapping (VSM) is presented. In the example approach, a user or practitioner logs into the VSM tool and begins creating value stream maps or workflows with key metrics added at each step of the map or workflow. Once a value stream map is completed, the user may generate reports that display key metrics such as task time, idle time, step value, number of hand-offs by role, total process cost, Lean wastes, etc. Metrics may be recalculated and the reports revised accordingly instantaneously. When a user logs out, his work will be saved, and will be available for the user or an authorized colleague when they log back on.

[0023] Turning to FIG. 1, an exemplary topology diagram of a cloud-based value stream mapping (VSM) approach for connecting numerous remote communication devices to a VSM tool in accordance with the invention, which is the FastTrax® Integrated VSM Tool 140. These remote communication devices may include a tablet computer 104, such as an iPad®, a workstation or desktop 106, a Smart phone 108, such as an iPhone®, and a laptop computer 110.

[0024] The remote communication devices are connected to a gateway server 118, which in turn connects to an Internet-based infrastructure (or "cloud') 120. The gateway server 118 enables remote communication devices' connection to a corporate network that includes the VSM Integrated Tool 140 from the Internet without having to set up virtual private network (VPN) connections. Through the Internet-based infrastructure 120, the remote communication devices may also be able to upload and utilize certain applications and services (apps) that allow these remote communication devices to communicate with the VSM Integrated Tool 140 in order to better generate the desired VSM reports. [0025] The VSM Integrated Tool 140 may also be in signal communication, through the cloud 120, with one or more enterprises, in FIG. 1 shown as building "A" 122 and building "B" 124. Users employed by or in association with these enterprises may also have access to the VSM Integrated Tool 140 in order to generate the VSM maps required by the enterprises.

[0026] It is appreciated by those skilled in the art that the cloud-based approach shown in FIG. 1 is only an exemplary topology diagram of a cloud-computing methodology and that for the purpose of connecting numerous remote devices with the VSM Integrated Tool 140, a cloud-based implementation may take other forms and include other components, such as internal and external firewalls, Web servers, proxy servers, and the like.

[0027] Once registered and logged in, a user is able to begin generating VSM state diagrams using the VSM Integrated Tool 140. An example of an interface 200 available to the user of the VSM Integrated Tool 140 is shown in FIG. 2. Using the interface of FIG. 2, the user has the first option to select an existing client, which as shown in the dropdown menu 206, is the "Cason Call Center." If the user wishes to add a new Client instead, he can do so by clicking on Add button 208. For the client Cason Call Center, Workflow Lists are shown in menu 204, where a single Workflow List named "Call Center New Hire Process" is shown. If the user wishes to add another Workflow List for the client Cason Call Center, he can do so by clicking on Add button 210.

[0028] Turning to FIG. 3, a Workflow List for the client Cason Call Center is shown, which the user has accessed by clicking on "Call Center New Hire Process" in menu 204 of FIG. 2. The Workflow List shows two steps 302, 304, already listed in the "Call Center New Hire Process" Workflow List. If the user wishes to add steps or tasks he or she can click on Add Step button 310, which results in add-step menu 320 being displayed.

[0029] FIG. 4 shows the add-step menu 320 of FIG. 3 in greater detail. Building value stream maps consists in part of inputting key information that will lead to generating a comprehensive report for the improvement of a process design. An example of a set of key metrics and their corresponding purposes are shown in Table 1 below. In this example approach, the key metrics of Table 1 are those applicable to a traditional manufacturing or service process. In the case of other processes, for example, a just-in-time process, additional key metrics may be added as needed.

Table 1: Key Metrics for Value Stream Mapping

[0030] Turning to FIG. 4, various Key Metrics may be entered by the user by way of add-step menu 402. For example, the Key Metric "Lean Waste" may be entered by a user from dropdown- menu 404, which lists eight different classifications of Lean Waste. The values "Value Added," "Limited Value," or "No Value Added" may be entered for Key Metric "Task Value" with buttons (see 322, FIG. 3). Values for Task Time and Idle Time may be entered directly into a step by entering times in blocks 410 and 412, respectively. Descriptions (i.e., names) for Input, Task, and Output may be entered directly into a step by entering the desired labels in blocks 420, 422, and 424, respectively. It is appreciated by those skilled in the art that parameters/values for Key Metrics may be entered by various methods, such as dropdown menus, buttons, direct data entry, etc.

[0031] FIGs. 5A, 5B, and 5C show a current state Workflow List of an example value stream mapping generated by a VSM tool in accordance with the invention. The Workflow List of FIGs. 5A, 5B, and 5C consists of sixteen steps that have been input by a user to create the Workflow List named "Call Center New Hire Process." This was done by the user utilizing the add step menu 310 of Fig. 3. A Workflow List may be displayed on a monitor by the user clicking on the Workflow tab 330 of Fig. 3.

[0032] FIGs. 6A and 6B show a Metrics report of the Workflow List shown in FIGs. 5A, 5B, and 5C, which may be displayed on a monitor by the user clicking on the Metrics tab 332 of Fig. 3. The Metrics reports may generally comprise various bar and pie charts and graphs. Likewise, FIG. 7 shows a list of the Opportunities and Alerts contained in the Workflow List shown in FIGs. 5A, 5B, and 5C, which may be displayed by the user clicking on the Opportunities tab 334 and the Alerts tab 336, respectively, of Fig. 3. Additional reports in different formats may also be available by clicking on the links in tab 352 of Fig. 3. Examples of such reports may include reports in PDF format that may be retrieved and stored by a user, as well as swimlanes reports, which generally are useful for processes containing numerous hand-off s. [0033] Once a user has completed a Workflow List for a particular process, he or she may generate the desired reports and review and analyze them. Based on the review and analysis, the user may then revise the Workflow List. As an example, if a customer advises a user that certain steps of a process have no value added, and are not subject to a regulatory requirement, the user may revise the Workflow List to delete or revise these steps. The tools to revise a Workflow List include the pencil icon and the "X" icon shown in tab 360 of Fig. 3, where the pencil icon is used to edit a step of a Workflow List and the "X" icon is used to delete a step. Also, the tab 362 may be used to move steps up or down in a Workflow List.

[0034] As an example of a revised Workflow List, FIGs. 8A, 8B, and 8C show a future state Workflow List of another example value stream map generated by a VSM tool in accordance with the invention, which in this case consists of the six steps of the Workflow List of FIGs. 5A, 5B, and 5C that have a Task Value other than "No Value Added." Additionally, the user will have access to the corresponding reports by way of the Metrics tab 332, the Opportunities tab 334, and the Alerts tab 336, of Fig. 3.

[0035] Turning to FIG. 11, this is a flow diagram of a method of generating value stream maps comprising current state diagrams and future state diagrams in accordance with the invention. The process starts in step 902 where a user logs into an integrated VSM tool. In step 904, the user may either generate a new Workflow List or edit a previously-existing Workflow List. The user then reviews and analyzes the reports, which may include those shown in FIGs. 5A, 5B, 5C, 6A, 6B, and 7 in step 906. In decision step 908, if the user determines that the Workflow List is satisfactory, then the process ends. [0036] If the user determines that the Workflow List is not satisfactory, the process proceeds to step 910, where further editing of the Workflow List takes place. In step 912, new reports are generated and these new reports are reviewed and analyzed in step 914. In decision step 916, if the user determines that the Workflow List is satisfactory, the process ends. Otherwise, the process proceeds to step 910, where the process repeats itself until a satisfactory Workflow List is generated. The repetitive process may be implemented by the user toggling between a current state and a future state utilizing the links in tab 350 of FIG.3. In step 918, when a satisfactory Workflow List is achieved, the future state diagram may become a current state diagram when the user exits the integrated VSM tool.

[0037] It will be understood, and is appreciated by persons skilled in the art, that one or more processes, sub-processes, or process steps described in connection with FIGS.2, 3, 4, and 9 may be performed by hardware and/or software. If the process is performed by software, the software may reside in software memory (not shown) in a suitable electronic processing component or system such as, one or more of the functional components or modules schematically depicted in FIGS.2, 3, 4, and 9. The software in software memory may include an ordered listing of executable instructions for implementing logical functions (that is, "logic" that may be implemented either in digital form such as digital circuitry or source code or in analog form such as analog circuitry or an analog source such an analog electrical, sound or video signal), and may selectively be embodied in any computer-readable medium for use by or in connection with an instruction execution system, apparatus, or device, such as a computer-based system, processor-containing system, or other system that may selectively fetch the instructions from the instruction execution system, apparatus, or device and execute the instructions. In the context of this disclosure, a "computer-readable medium" is any means that may contain, store or communicate the program for use by or in connection with the instruction execution system, apparatus, or device. The computer readable medium may selectively be, for example, but is not limited to, an electronic, magnetic, optical, electromagnetic, infrared, or semiconductor system, apparatus or device. More specific examples, but nonetheless a non-exhaustive list, of computer-readable media would include the following: a portable computer diskette (magnetic), a RAM (electronic), a read-only memory "ROM" (electronic), an erasable programmable read-only memory (EPROM or Flash memory) (electronic) and a portable compact disc read-only memory (CDROM) (optical). Note that the computer- readable medium may even be paper or another suitable medium upon which the program is printed, as the program can be electronically captured, via for instance optical scanning of the paper or other medium, then compiled, interpreted or otherwise processed in a suitable manner if necessary, and then stored in a computer memory.

[0038] The foregoing description of implementations has been presented for purposes of illustration and description. It is not exhaustive and does not limit the claimed inventions to the precise form disclosed. Modifications and variations are possible in light of the above description or may be acquired from practicing the invention. The claims and their equivalents define the scope of the invention.

[0039] It will be understood that the term "in signal communication" as used herein means that two or more systems, devices, components, modules, or sub-modules are capable of communicating with each other via signals that travel over some type of signal path. The signals may be communication, power, data, or energy signals, which may communicate information, power, or energy from a first system, device, component, module, or sub-module to a second system, device, component, module, or sub-module along a signal path between the first and second system, device, component, module, or sub-module. The signal paths may include physical, electrical, magnetic, electromagnetic, electrochemical, optical, wired, or wireless connections. The signal paths may also include additional systems, devices, components, modules, or sub-modules between the first and second system, device, component, module, or sub-module.

[0040] More generally, terms such as "communicate" and "in . . . communication with" (for example, a first component "communicates with" or "is in communication with" a second component) are used herein to indicate a structural, functional, mechanical, electrical, signal, optical, magnetic, electromagnetic, ionic or fluidic relationship between two or more components or elements. As such, the fact that one component is said to communicate with a second component is not intended to exclude the possibility that additional components may be present between, and/or operatively associated or engaged with, the first and second components.

[0041] It will be understood that various aspects or details of the invention may be changed without departing from the scope of the invention. Furthermore, the foregoing description is for the purpose of illustration only, and not for the purpose of limitation— the invention being defined by the claims.

Claims

CLAIMS What is claimed is:

1. A method of value stream mapping, the method comprising:

generating steps comprising a process from a web-based interface;

integrating key metrics into each of the steps;

calculating additional key metrics from the integrated key metrics; and

generating reports displaying the key metrics and the additional key metrics in graphical layouts.

2. The method of claim 1, further comprising the steps of:

reviewing the reports;

responsive to the review, editing one or more steps of the process; and

generating second reports of the edited process in graphical layouts.

3. The method of claim 1, where the step of editing one or more steps includes deleting a step and modifying a key metric of a step.

4. The method of claim 1, where the key metrics are selected from a set of key metrics available on the web-based interface.

5. The method of claim 1, where the process is a manufacturing process.

6. The method of claim 1, where the process is a business services process.

7. The method of claim 1, where the reports comprise workflow lists, swimlanes reports, and bar and pie charts displaying key metrics.

8. A value stream mapping system ("VSMS"), whereby a plurality of users may generate value stream maps over a network, the VSMS comprising:

a user interface module in signal communication with each of the plurality of users, whereby the user interface module is configured to receive data from each user related to a value stream map created by each user individually,

where the user interface module includes predefined key metrics available to the user for integrating into the value stream map; and

an output report module in signal communication with the user interface module, where the output report module is configured to generate reports of value stream maps that include graphic displays of key metrics integrated into the value stream map.

9. The VSMS of claim 8, further including a value stream mapping module in signal communication with the user interface module configured to integrate selected key metrics into a value stream map as determined by the user and to calculate additional key metrics based on the integrated selected key metrics.