Value Stream Mapping Project Template

© Operational Excellence Consulting. All rights reserved.
Value Stream Mapping
Project Template
Template for compiling a value stream improvement
storyboard from current state mapping to future state
design implementation

4
Name of VSM Project Team (e.g. Muda Busters)
Insert your team photo here.
This document is a partial preview. Full document download can be found on Flevy:
https://flevy.com/browse/document/value-stream-mapping-project-template-1100

7
Value Stream Mapping Roadmap
Create
Implementation
Plan
Design
Future
State Document
Current State
Define
Product
Family
Define and scope
problem
Pick product family
Determine VSM objective
and benefits
Create VSM charter
Map current state value
stream
Quantify current state
value stream performance
Analyze and identify
improvement
opportunities
Develop future state
value stream map
Prioritize improvement
projects
Develop implementation
plan
Seek management
approval
Implement the plan
and monitor
progress
1
2
3
4

10
Considerations & Approach
• What are the current and future demand rates?
• Is the VSM showing what happens 80 percent of the time to reduce
variation and focus on improving the majority of the work?
• If it is prudent to focus initially on the 20% that are the exceptions,
the charter should clearly define the specific conditions being
mapped and the reasons for focusing on the exceptions.
Alternatively, the space here can be used.
• Is the VSM depicting the flow of an average lot size or work that
happens on a typical shift or others?
• <Add other relevant information if necessary to help the audience or
reader understand the VSM>

13
Define Phase Deliverables
• VSM charter
• VSM Manager sign-off
• Executive Sponsor sign-off
• Communication plan

16
Basic Mapping Symbols
External
Organization
Process Block
Data Block
Work-in-Process
In-box
Push Arrow
Material Receipts
& Shipments
Manual
Information Flow
Electronic
Information Flow
Operator / Employee
Go See Scheduling
Movement by Truck
Minutes MinutesMinutesMinutes
HoursHoursHoursLead Time
Cycle Time
Timeline
Takt = 60 min
2 Shifts
CT = 25 min
C/O = 25 min

19
Current State Value Stream Map
Demand all families =
100 pcs/day.
Demand family A =
35 pcs/day.
2 shifts.
Takt time = 532 sec.
Customers
Machining
Ct = 420s
Co = 20m
Up = 70%
☺ = 1
Shifts = 3
Drilling
Ct = 145s
Co = 15m
Up = 50%
☺ = 1
Shifts = 2
Welding
Ct = 185s
Co = 8m
Up = 70%
☺ = 1
Shifts = 2
Assembly
Ct = 360s
Co = 7m
Up = 80%
☺ = 1
Shifts = 2
Packaging
Ct = 40s
Co = 3m
Up = 15%
☺ = 1
Shifts = 2
Suppliers
MRP
Weekly plan
Forecasts =
30 days
Daily orders
Continuous
forecasts
Daily orders
58 days 6 days 9 days 5 days 2 days 42 days
420 sec 145 sec 185 sec 360 sec 40 sec
Component A =
35 pcs per/day.
Orders are placed
on demand.
Lead time from order
is placed= 2 days.
2030 pcs 210 pcs 315 pcs 175 pcs 70 pcs 1470 pcs
= 122
days
=1150
sec.
Current state value stream map should show the key
process activities. Show the timeline below the current state
value stream.
ILLUSTRATIVE

22
Analysis of the Eight Types of Waste
Over-production
Inventory
TransportationDefects
Over-processing Motion
Intellect Waiting
Waste
Analyze opportunities to reduce the various types of waste.

25
Current State Findings & Analysis
15%
20%
65%
Value Add (VA)
Necessary Non-Value
Add (SNVA)
Unnecessary Non-
Value Add (UNVA)

28
Analysis of Current State Work Sequence
Analyze the work sequence and identify waste elimination
opportunities, e.g. motion.
ILLUSTRATIVE

31
Current State Mapping Phase Deliverables
• Operational definitions of each metric in the data box
• Current state value stream map
Process boxes
Data boxes
Timeline Metrics
Lead Time
Process Time
Quality
• Current state plant layout/spaghetti diagram
• Current state results
• List of current state analysis and findings

34
Develop Future State Value Stream Map
Demand all families =
100 pcs/day.
Demand family A =
35 pcs/day.
1 shift.
Takt time = 266 sec.
Customers
Machining
Ct = 420s
Co = 5m
Up = 85%
☺ = 1
Shifts = 2
U-Cell
Ct = 250s
Co = 1-3m
Up = 65-80%
☺ = 4
Shifts = 1
Suppliers
MRP
Daily plan
Forecasts =
30 days
Daily orders
Continuous
forecasts
Daily ordersComponent A =
35 pcs per/day.
Orders are placed
on demand.
Lead time from order
is placed= 2 days.
Goal 700 pcs Goal 140 pcs Goal 70 pcs
Kanban
U-cell
Orders
20 days 4 days 2 days
Sum = 730 sec
= 26
days
=1150
sec.
420 sec
Kanban
Changeover time
Increase OEE
Physical layout
Flow between
work stations
etc.
Daily
planning
Changeover times
Increase OEE
Task distribution
ILLUSTRATIVE
Define the future state value stream map. Highlight “Kaizen
bursts” to indicate proposed improvements.

37
Metric Current State Goal Projected Future State % Improvement
Timeline Lead Time
Timeline Cycle Time
% Activity
Rolled First Pass Yield
# Employees
Floor Space Used
# Shifts
Add Other Relevant Metrics
Future State Value Stream Mapping Results (Projected)

40
Future State Mapping Phase Deliverables
• Future state value stream map
Process boxes
Data boxes
Estimated Timeline Metrics
Lead Time
Process Time
Quality
• Future state plant layout/spaghetti diagram
• Future state results (projected)
• Prioritized list of improvement projects / kaizens / just-do-its.
Estimate the benefits (e.g. productivity gains, cost savings, FTE
savings, etc.) for each project.

43
Implementation Plan
Future State Implementation Plan
Value Stream Implementation Plan Review Dates
Executive Sponsor
Value Stream Champion
Value Stream Mapping Facilitator
Date Created
Block # Goal / Objective Improvement Activity Owner
Implementation Schedule (weeks) Date
1 2 3 4 5 6 7 8 9 10 11 12 Complete
Approvals
Executive Sponsor Value Stream Champion Value Stream Mapping Facilitator
Signature: Signature: Signature:
Date: Date: Dates:

46
Implementation Phase Deliverables
• Implementation plan
• VSM Manager sign-off
• Executive Sponsor sign-off
• Implementation progress monitoring and updates to stakeholders
• Lessons learned
• Share success story and celebrate success

Appendix 1 – Value Stream Mapping
Icons

55
Value Stream Mapping Symbols
Symbol Name Description
Data Box
This symbol is placed under any
symbol to display critical information.
Typically it displays information such
as frequency of shipment, batch size,
material information underneath
external sources symbol. For the
process symbol, it typically display
information such as cycle time,
change over time, uptime, processing
time, available capacity, batch size,
yield, etc.
Inventory
Represents the level of inventory
before a process. The level of
inventory is displayed below the
symbol.

58
Value Stream Mapping Symbols
Symbol Name Description
Pull
Arrow/Withdra
wal
Represents the pull of material. It is
used when the current process ‘pulls’
materials from the preceding process.
FIFO Represents first-in-first-out inventory.
Withdrawal
Kanban
Used to signal withdrawal of parts
from a supermarket.
Production
Kanban
Used to signal an upstream process to
produce parts for a downstream
process, usually a pre-defined
quantity.
Kanban Post
Represents a location where Kanbans
are placed.

Appendix 2 – Value Stream Mapping
Template

64
Common Current State Findings
• Loopbacks
• Unnecessary handoffs
• Rework due to errors and lack
of clarity
• Functions missing or getting
involved too early or too late in
the process
• Redundant activities
• High variation in how work is
performed
• No documented standard work
• Excessive inspection (review,
approval, audits)
• Overspecialization of staff
• Existing technology not fully
leveraged
• Underutilization of skills
• Compliance overkill
• Delays due to juggling multiple
responsibilities
• Overburden (Muri)

1
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