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How can you use value stream mapping to improve your inventory control system?

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If you want to optimize your inventory control system, you need to understand how your materials, information, and processes flow from the supplier to the customer. Value stream mapping (VSM) is a powerful tool that helps you visualize and analyze your current and future state of value creation. In this article, you will learn how to use VSM to identify and eliminate waste, improve efficiency, and reduce costs in your inventory control system.

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Adi Nugroho

Content Creator for Education in Supply Chain, Supply Chain Enthusiast, Continues Improvement

1 What is value stream mapping?

Value stream mapping is a lean manufacturing technique that uses symbols and data to represent the flow of materials and information along a value stream. A value stream is the sequence of activities that deliver value to the customer, such as design, production, delivery, and service. VSM helps you see the sources of waste, variability, and inefficiency in your value stream, and design a future state that eliminates or minimizes them.

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2 How to create a value stream map?

In order to create a value stream map, you must first define the scope and objective of the project. Then, collect data on the current state by walking the gemba and observing the flow of materials and information. After that, draw a current state map using standard symbols and formats to represent the main elements. Analyze the map to identify value-added and non-value-added activities, as well as calculate performance metrics. Next, envision the future state by brainstorming improvement ideas that can reduce waste and increase value. Draw a future state map that includes expected benefits and targets. Finally, develop an action plan with tasks, resources, responsibilities, and timelines for implementation. Assign owners and champions for each improvement initiative and monitor progress.

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3 How to use VSM for inventory control?

Inventory control is the process of managing the quantity, location, and movement of materials in your value stream. It seeks to balance supply and demand, minimize costs, and guarantee product availability and quality. Through VSM, you can gain insight into current inventory levels and locations, identify the causes of overstocking or understocking, and suggest solutions to optimize inventory levels and flows. For instance, you can apply lean techniques, such as pull systems, kanban cards, point-of-use storage, and cycle counting to reduce your inventory while meeting customer demand. Additionally, you can improve information systems like ERP, MRP, and barcodes to enhance inventory visibility and accuracy. These measures can help you understand how inventory affects your value stream performance in terms of space utilization, cash flow, customer service, and waste generation.

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Sudipta Banerjee

In Pursuit of Excellence
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Value Stream Mapping (VSM) fosters cross-functional communication by engaging multiple departments in the mapping process. Enhanced communication ensures well-coordinated inventory control measures, thereby minimizing the risks associated with overstocking or stockouts.

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4 What are the benefits of VSM for inventory control?

VSM can offer several benefits for your inventory control system, such as lowering inventory costs, increasing inventory turnover, improving inventory quality, and enhancing customer satisfaction. By reducing your inventory levels, you can save on storage, handling, transportation, and obsolescence costs, as well as freeing up working capital to invest in other areas. Additionally, by increasing your inventory turnover you can improve your cash flow and profitability, as well as reduce the risk of shrinkage or damage. Furthermore, minimizing your inventory can ensure that materials are fresh and in good condition. Optimizing your inventory flows can also result in faster and more reliable product delivery to customers and the ability to respond more flexibly to changing customer needs.

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Adi Nugroho

Content Creator for Education in Supply Chain, Supply Chain Enthusiast, Continues Improvement
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VSM mapping is the basic core to understanding the business excellence of our company. It gives you overview how business work, tell you information flow such as cycle time, takt time, etc and material flow. It gives you most overview of how company works. After you know it, then it will give you understanding the strategy how to overcome the fluctuation, seasonal, and so on. It helps a lot on how to reduce inventory. Actually not just inventory, you can remove unnecessary flow process, reduce leadtime, cycle time, and many more in waste. Should you focus on how to remove on waste, so it is so important how to create value stream correctly.

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5 How to sustain VSM for inventory control?

VSM is not a one-time event, but a continuous improvement process. To sustain VSM for inventory control, you need to review and update your value stream maps regularly, as business conditions and customer demand change. Additionally, it’s important to engage and empower your employees by training them on VSM and lean concepts, as well as soliciting their feedback and suggestions. Lastly, make sure to align and integrate your VSM with your business strategy and goals. This will ensure that VSM objectives and targets are in line with the business vision and mission, and that VSM activities are integrated with other business processes.

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Sudipta Banerjee

In Pursuit of Excellence
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Integrating Value Stream Mapping (VSM) with Quality Circle (QC) initiatives enables the identification of opportunities for optimizing inventory management within the process. Through this collaborative approach, organizations can precisely identify areas for improvement, boost efficiency, and streamline the overall inventory control process. The combination of VSM's visual insights and Quality Circles' problem-solving capabilities empowers companies to establish more effective and sustainable inventory management practices.

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6 Here’s what else to consider

This is a space to share examples, stories, or insights that don’t fit into any of the previous sections. What else would you like to add?

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Joseph Jendrus

Associate Director, Quality - Polysaccharide Vaccines Environmental Monitoring at Merck
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Consider implementing changes incrementally. In doing so, you minimize the risks associated with large-scale transformations, allowing for a more controlled and adaptive approach to improving your inventory control system.

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Sudipta Banerjee

In Pursuit of Excellence
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Value Stream Mapping (VSM) is poised to incorporate increasingly sophisticated data analytics tools and technologies, offering enhanced insights into inventory flows, demand patterns, and areas for potential improvement. The utilization of predictive analytics is anticipated, enabling more accurate demand forecasting and empowering proactive and strategic approaches to inventory management.

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How can you use value stream mapping to improve your inventory control system?

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5

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1 What is value stream mapping?

2 How to create a value stream map?

3 How to use VSM for inventory control?

4 What are the benefits of VSM for inventory control?

5 How to sustain VSM for inventory control?

6 Here’s what else to consider

Manufacturing

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How can you use value stream mapping to improve your inventory control system?

1

2

3

4

5

6

1 What is value stream mapping?

2 How to create a value stream map?

3 How to use VSM for inventory control?

4 What are the benefits of VSM for inventory control?

5 How to sustain VSM for inventory control?

6 Here’s what else to consider

Manufacturing

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