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Value-Stream Mapping for Manufacturing: Gemba-Based Workshop (3 Day Class)

The blueprint for lean transformations, a value-stream map (VSM) is a paper-and-pencil representation of every process in the material and information flow along with key data. It differs significantly from tools such as process mapping or layout diagrams because it includes information flow as well as material flow. Among other benefits, VSMs can help you:

  • Reveal where lean techniques, such as kaizen events, could be utilized for maximum effect.
  • Avoid the common mistake of “cherry-picking” individual lean techniques, which creates isolated islands of improvement and limited benefits.
  • Improve the overall flow of value to the customer and deliver the biggest benefits.
  • Identify and eliminate waste

This workshop shows you how to create and apply this fundamental and critical tool, based on Lean Enterprise Institute's groundbreaking VSM workbook, Learning to See, which has introduced the mapping tool to thousands around the world. As part of the learning process, participants will practice the Value Stream Mapping cycle in a real manufacturing environment under the guidance of an experienced LEI faculty member.  This rare opportunity will help embed the learning through an experiential activity in a fast-paced, critical operation.

Workshop Outline

This workshop will sharpen your "eyes for waste" and "eyes for flow." Using a manufacturing case study you'll learn how to identify a product family, how to see the entire value stream for a particular product family, how to map the value stream to identify and eliminate waste, what makes a value stream lean, and how to develop a plan to achieve results.

After receiving a manufacturing case study overview on Day One, participants will create a VSM based on their observations at a real manufacturing gemba. Participants will spend Day Two mapping out the current state for one product value stream.  On Day Three, participants will create a future state design and an action plan for achieving the future state.  

 Workshop topics include:

  • Value-stream improvement vs. process improvement
  • Exercise: Drawing a current-state map
  • What is a lean flow?
  • Individual efficiency vs. system efficiency
  • Build to supermarket or to shipping?
  • Continuous flow processing
  • Scheduling one point
  • Designing a lean flow
  • Exercise: Drawing a future-state map
  • How to create a plan for implementing the future state 

Learning Objectives:
At the end of the workshop you should be able to:

  • Understand and explain to others the benefits of value-stream mapping
  • Draw a current state map
  • Identify major lean concepts
  • Draw a future state map
  • Develop a basic implementation plan

Who Should Attend:
Those who would benefit from attending this workshop include:

  • Operators, engineers, managers, supervisors, technical support personnel and change agents in any industry with multi-step processes
  • Organizations at any level of a lean journey, particularly (though not exclusively) those just beginning

Suggested Reading:

This workshop assumes you are familiar with basic lean terms and concepts as described in Lean Thinking by Jim Womack and Dan Jones. For maximum benefit we strongly recommend that you read Learning to See by Mike Rother and John Shook to develop a value stream perspective before attending the workshop. (Lean Thinking and Learning to See have received Shingo Research Prizes. This workshop is based on the Learning to See workbook.)


Workshop Suggestion:
To maximize your learning experience we recommend that prior to attending this program you take following workshop or have a good understanding of the concepts presented within it.
Suggested Reading for this Workshop:
This program is offered at customer facilities only, as an on-site workshop. If you have any questions or want to bring this workshop to your organization, please contact us at info@lean.org or 617.871.2900.