How do you apply value stream mapping to visualize and improve the flow of materials and information?

2 How to create a current state map?

To create a current state map, you need to collect data and observe the actual process in action. You can use a standard VSM template or create your own symbols and notations. The main elements of a current state map include process steps, inventory, information flow, and metrics. To record data and information, you can use a stopwatch, clipboard, camera, or spreadsheet. Additionally, interviewing workers, managers, and customers can provide their perspectives and insights. Drawing the current state map on a large paper or whiteboard should be done with validation from stakeholders. Process steps refer to activities that transform the input into the output; inventory covers materials or products waiting between steps; information flow is communication and coordination between steps; metrics are quantitative measures of performance such as cycle time, lead time, throughput, defect rate, etc.

3 How to analyze a current state map?

Analyzing a current state map requires you to identify and quantify the waste and inefficiency in the process. Waste can be anything that does not add value to the customer or consumes more resources than necessary, and there are seven types of waste in lean manufacturing: overproduction, waiting, transportation, inventory, motion, overprocessing, and defects. To calculate the waste and inefficiency in the process, you can use tools such as value-added analysis, spaghetti diagram, takt time, cycle time ratio, and overall equipment effectiveness. It is also important to look for the root causes of the problems and opportunities for improvement.

4 How to create a future state map?

To create a future state map, you need to design and implement solutions that eliminate or reduce the waste and inefficiency in the process. Lean principles and techniques such as pull system, continuous flow, work cell, standard work, poka-yoke, and kaizen can be used to achieve this. Pull system is about producing only what the customer needs and when they need it; continuous flow is about minimizing the batch size and the inventory between the process steps; work cell is about grouping the process steps and the workers into a compact and integrated unit; standard work is about defining and documenting the best practices and procedures for each process step; poka-yoke is about preventing or detecting errors and defects in the process; kaizen is about continuously monitoring and improving the process performance. Drawing the future state map on the same paper or whiteboard as the current state map, comparing metrics and benefits, developing an action plan with a timeline to implement changes, and achieving the future state are all important steps.

5 How to sustain a future state map?

To sustain a future state map, you need to ensure that the changes are embedded and maintained in the process. Visual management, 5S, gemba walk, audit, and feedback are all tools that can be used to achieve this. Visual management involves displaying process information and performance indicators in an accessible way, such as charts, boards, signs, or colors. 5S refers to organizing and standardizing the workplace with five steps of sort, set in order, shine, standardize, and sustain. Gemba walk is a process of visiting and observing the actual process and workers, using open-ended questions and respectful listening. Audit involves checking and verifying the compliance and effectiveness of the process with checklists, scorecards, or audits. Feedback collects and analyzes customer feedback using surveys, interviews, or reviews. Additionally, a culture of continuous improvement and learning should be fostered to involve workers, managers and customers in the VSM process. The VSM should also be reviewed and updated regularly to reflect changes and improvements.

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?