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Value-Stream Mapping for Manufacturing (1 Day Class)

Value-stream maps are the blueprints for lean transformations. This workshop shows you how to make and apply this fundamental and critical tool, based on the Lean Enterprise Institute's groundbreaking value-stream mapping workbook, Learning to See, which has introduced the mapping tool to thousands of people around the world.

The value-stream map is a paper-and-pencil representation of every process in the material and information flow of a product or product family, 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.

Mapping is a critical initial step in lean transformations because it shows you where you could apply lean techniques, such as kaizen events, for maximum effect. Mapping helps you avoid the common mistake of cherry-picking individual lean techniques, which creates isolated islands of improvement and limited benefits. The mapping cycle of mapping current conditions then quickly drawing and implementing a leaner future state improves the overall flow of value to the customer and delivers the biggest benefits.

Through instruction, discussion, group activities, and hands-on exercises, this workshop will show you how to see value, differentiate value from waste, and eliminate the sources of waste by creating accurate current-state maps and leaner future-state maps for a product family. You'll also develop plans for implementing the future state. Mapping helps you:

  • Establish a direction for the company’s improvement efforts – maps become the blueprints for the lean transformation
  • Target kaizen activities for bigger and more sustainable impact
  • Gain a better understanding of the linkages between material and information flow
  • Visualize improvements to the overall production flow, instead of spot improvements to single processes
  • Create the basis for an effective lean implementation plan by designing how a facility’s door-to-door material and information flow could operate
  • Give operators, engineers, and managers a common language and process for continuous improvement

Course 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. 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
  • Any industry with multi-step processes
  • Organizations at any level of a lean journey, particularly (though not exclusively) those just beginning

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 Deborah McGee, Learning Activities Manager at dmcgee@lean.org or 617.871.2944.