Value Stream Mapping
Event 

            Understanding the concepts of Lean / World Class Enterprise is one thing.  Determining how and where to apply them is another.  Transforming to a Lean / World Class Enterprise can seem like a daunting task.  “Where do we start?” “How do we go about implementing?”  That is where Value Stream Mapping can help.

Value Stream Mapping is a method to visually depict material and information flows through an operation.  A cross functional team will develop a Current State Map to depict these flows.  Further, the team will collect vital information which enables a company to identify the issues that must be addressed.  Then the team works to develop a vision of “what can-be” – a Future State Map.  Here the team works to apply the various Lean Enterprise concepts such as Cellular/Flow and Pull/Kanban Systems.  In addition, specific improvement needs are identified such as: improving machine uptime through Total Productive Maintenance; improved process and product quality through Quality Management; set-up/changeover reduction through Quick Changeover techniques.

At this point, the team identifies the potential benefits in terms of lead time, inventory turns, and other benefits.  But wait!  The FutureState can represent a big change in the way the company currently operates.  “How will we ever get there?”  The Future State Map is broken down into “loops” – specific segments of the value stream that will be addressed sequentially over time.  The identification of several loops helps to make what seems to be an impossible task more realizable.  The team can then develop an implementation strategy – a 6-12 month plan to make the FutureState a reality, addressing one “loop” after another.

Typical 2-Day Agenda

Pre-event:

• Scoping exercise – to prepare for mapping event

Day 1:            

• Education in basic concepts
• Complete example Case Study
• Complete Current State Map for an identified Product Family within the operation

Day 2:            

• Develop Future  State Map
• Identify “loops”
• Develop Implementation Strategy

Typical 2-Day Agenda (continued)

The actual number of days required will depend on the complexity of the product family that is the subject of the mapping event.  In particular, the time required to complete the current state map will depend on the number of processes involved, and the total work content.  In general approximately 15 – 20 minutes per process box is required.  Therefore, for eight main process boxes, a total of about 3 hours will be required to map the current state.

Typical Deliverables 

• A cross functional team of people who will be able to apply Value Stream Mapping techniques to other Value Streams in the company.
• A vision of what “can-be” for a particular product family, along with expected benefits.
• An implementation strategy to make the vision a reality.

Value Stream Mapping
One-day Workshop 

            Understanding the concepts of Lean / World Class Enterprise is one thing.  Determining how and where to apply them is another.  Transforming to a Lean / World Class Enterprise can seem like a daunting task.  “Where do we start?” “How do we go about implementing?”  That is where Value Stream Mapping can help.  It is the assessment and planning tool for lean practitioners.  The workshop is based on the landmark book “Learning to See” by Rother and Shook.

Value Stream Mapping is a method to visually depict material and information flows through an operation.  A cross functional team will develop a Current State Map to depict these flows.  Further, the team will collect vital information which enables a company to identify the issues that must be addressed.  Then the team works to develop a vision of “what can-be” – a Future State Map.  Here the team works to apply the various Flow/Lean concepts such as Cellular/Flow and Pull/Kanban Systems.  In addition, specific improvement needs are identified such as: improving machine uptime through Total Productive Maintenance; improved process and product quality through Quality Management; set-up/changeover reduction through Quick Changeover techniques.

At this point, the team identifies the potential benefits in terms of lead time, inventory turns, and other benefits.  But wait!  The FutureState can represent a big change in the way the company currently operates.  “How will we ever get there?”  The Future State Map is broken down into “loops” – specific segments of the value stream that will be addressed sequentially over time.  The identification of several loops helps to make what seems to be an impossible task more realizable.  The team can then develop an implementation strategy – a 6-12 month plan to make the FutureState a reality, addressing one “loop” after another.

This one day workshop will provide a basis of understanding for the use of this important lean tool.  By use of a case study, the participants will develop the requisite skills to develop value stream maps, as well as to begin to apply Lean Thinking.

Duration:          1 day

Who should attend:  anyone who works in a manufacturing, including managers.  People who support the production operation can also benefit by attending this workshop.