Value stream mapping (VSM) is a graphical tool used to visualize the flow of processes and information in manufacturing and other industries, aimed at eliminating waste and improving efficiency. The process involves gathering data, creating current and future state maps, and executing plans for improvement while focusing on activities that add value. Key roles in a VSM study include executive sponsors, process owners, VSM coaches, and workshop participants, all of whom collaborate to facilitate successful project outcomes.

1. Mouhcine NAHAL
mouhcine.nahal@gmail.com

2. What is Value Stream Mapping?
→ Value Stream Mapping is a graphical tool that helps us to see and understand the flow of process and
information as a product and service.
→ It is an improvement tool that is visualizing the entire operation of manufacturing or service representing
both material and information flow.
→ It is one of the best Lean Tool to eliminate waste.
→ A value stream usually includes people, tools and technologies, physical facilities, and communication
channels, etc...
→ This tool is associated with the manufacturing industry in major cases.
→ It can also be applied in various industries like Product development, Service-related industries:
e.g. healthcare, insurance, hospitality, and logistics, etc…
→ VSM Study is one of the important in the Lean Six Sigma Project.

3. History:
→ T. Ohno from Toyota Production gave the concept of a Value Stream Mapping in 1988.
→ It was introduced as 'Material and Information Flow Mapping’.
→ Later it is named as Value Stream Mapping by John Shook and Mike Rother.
→ Value Stream Mapping puts all the information in one place and it is a very much effective method
as compared to other tools.
→ This tool is also used in Six Sigma Projects.

4. What is Value?
→ "Value" is a product or service that the customer is buying.
→ It is the capability to provide a product or a service having the highest quality, at an appropriate
price, and at the right time as defined by the customer.
→ Customer’s expectation of value may be, price, quality, reliable delivery, rapid response to changing
needs, etc.……

5. What is a Value Stream?
→ “Value Stream” is to identify the wasteful activity from the system and eliminate it from the system.
→ This happens by checking all small activities from start to end which is necessary to convert all
input into an output.
→ The value chain refers to all of the activities within an organization.
→ While a Value Stream focuses on that activity which adds value in a service or in a product.

6. Different things flow through the Stream:
→ In manufacturing or distribution, materials flow.
→ Patients flow in health services
→ Information flows in office areas.
→ Internal customer flows in administration.
→ So, in various system services, information, or product flow.

7. Reason for Mapping & Analysis :
→ Find out the relationship between operation steps
→ We can get information and also we can have an actual illustration of the current process
→ For setting the improvement targets for the organization
→ Identify improvement opportunity
→ Provide product or service the highest quality, at an appropriate price, and at the right time as
defined by the customer
→ Design (concept to a customer)
→ Build (order to delivery)
→ Sustain (in-use through the life cycle to service)

8. Objectives:
→ To identify improvement possibilities in the entire operation flow and supply chain.
→ By eliminating lean wastes and improve the performances.
→ To improve efficiency.
→ Satisfy our customers with our service.
→ Performance improvement of the operation.

9. Team Members and Roles in VSM Study Project:
1. Executive Sponsor
2. Process Owner
3. VSM Coach (Facilitator)
4. Workshop/office Participants

10. Team Members and Roles in VSM Study Project:
[1] Executive Sponsor:
→ Executive Sponsor is the owner of the Charter
→ He/She decide the team members for the project
→ Executive Sponsor is responsible for ensuring the member's participation.
→ Ongoing project status is presented by the Executive Sponsor.
→ He/She takes part in define the scope, start the project, Active team member of review, audit &
follow-ups committee

11. Team Members and Roles in VSM Study Project:
[2] Process Owner:
→ They are responsible for the whole operation flow and they lead the VSM project from beginning to
end.
→ They take ownership during the VSM event
→ All meetings, progress, and MOMs are maintained by the Process Owner.
→ Ensures action item pre-work is complete for scoping, workshop/office, and reviews
→ Conduct the review of the implementation plan at a certain interval.
→ He/She gives information to sponsor about the progress of the project.

12. Team Members and Roles in VSM Study Project:
[3] VSM Coach:
→ VSM coach provides coaching to Process Owner and team.
→ He/She is responsible for defining the scope of the project.
→ Gives training to the VSM team and give coaching to the team.
→ VSM Coach gives training on Lean Manufacturing to the team.
→ Provide training on lean skills to all participants.

13. Team Members and Roles in VSM Study Project:
[4] Workshop/office Participants:
→ Participate in the VSM project as a Subject Matter Expert (SME)
→ All Workshop/office Participants are responsible for the operation steps.
→ They support the VSM project successfully run.

14. How to create a Value Stream Mapping?:
→ It is a team exercise so all department representatives should participate in this event.
→ This project should be lead by the expert and can guide other team members for the successful
project.
→ The best method of making Value Stream Mapping is by hand using a pencil and A3 drawing sheet.
→ During creating the process map all participants should be involved in this activity is always a
better decision.
→ Begin with a quick walk through the entire operation
→ Always trust on your own taken data
→ Map the whole operation flow yourself.

15. Value Stream Mapping Process with example
→ Refer below five steps for understanding the full concept
1. Gather Data & Information
2. Create a Current State Map
3. Future State Map & Action Plans
4. Execute the Plan
5. Align

16. Step 1 - Gather Data and Information:
→ Refer below five steps for understanding the full concept
→ Gather Information:
→ Define the start & end of the operation flow
→ Define the criteria for data collection
→ Walk and observe the actual workplace
→ Take all the information related to each and every step.
→ Measure actual lead time, actual cycle time, on-time delivery rate, and defect rate, etc...

17. Step 2 - Create a Current State Map
→ Refer below five steps for understanding the full concept
→ Record the detail about the current flow material or information.
→ Make an analysis of the data
→ In the current state of the VSM study, we have to mention the actual readings or data of the
operation flow.
→ In this stage, we do not have to worry about the future of the process.
→ We have to mention just as the process is and it should show the real picture of the ongoing
operation flow.
→ Then after we can check the possibility of improvement.

18. VSM Study Symbols:
→ We need to understand the symbols that are using in the VSM study that is mentioned below.
→ The different symbols are used for a different activity that is mentioned in the below picture.
→ By using these symbols we can make a more clear understanding of the process.

19. Collecting Data and Time Studies in VSM Study:
→ We need to understand the symbols that are using in the VSM study that is mentioned below.
→ This is a very important step in the entire study.
→ There are a few ways in which we get information.
→ The first, we get the data directly from the industry by contacting all relevant personnel.
→ Take the operation sequence flow and work instruction data from the company, as well as
observed.
→ The process in actual, and conduct own time studies to get exact information about the
processing time.
→ During the walk carefully observe all operation steps and ask as many as possible questions.
→ And collect all data related to that operation.

20. Examples of data required in this study:
→ No. of work in progress
→ Cycle Times for each operation
→ Inspection or testing time
→ Check for the wasteful activity
→ Waiting time and working time etc…

21. Process Steps in VSM Study:
→ Mention the process flow as actual it is.
→ Write down all operation steps in the format box and add all data in this box.
→ Note down inventory days, delay time, wait time, and working time
→ Then calculate all working time and waiting time.
→ Find out the Process Cycle Efficiency as calculation mentioned in the below picture.

22. Analysis of the Current State Map:
→ Mention the process flow as actual it is.
→ The current state map is a way of saying “what happens now” or the “as-is”.
→ It should provide all process-related information like how the items are being processed and what
happens in each step?
→ This information helps us to find out the root cause of problems.
→ So we can improve our operation flow by eliminating the root cause.
→ And we can improve the operation efficiency, reliability, and flexibility..

23. Step 3 – Future State Map & Action Plans:
→ Discuss the ideal state
→ Develop the future state map & action plan
→ Build a draft timeline for implementation
→ Communication & training as required

24. Creating an Ideal and Future State
→ Discuss the ideal state
→ Define what we want to achieve the target so that we can focus our efforts on achieving our future
State.
→ The expert should create an ideal state map for the operation flow.
→ The simplest way to achieve the target is to plan a series of improvements and divide into various
lean events like 5S Methodology, Do-it, Burst, Kaizen Event, and Project.
→ We can highlight the improvement opportunity by using a kaizen burst symbol on our current state
map.

25. Analysis of Future State Map:
→ In the future state, map analyzes and reduces the waiting time, so overall time will decrease and
performance will increase.
→ By using a Pareto chart or ABC analysis we can easily find our the bottleneck area where we have
to work on a priority basis.
→ Then take any bottlenecked process and further analyze on a micro basis, find out the improvement
scope and eliminate the wastes.

26. Step 4 – Execute the Plan:
→ Implement improvements
→ Conduct Workshops, events, projects, bursts per the implementation plan
→ Achieve value stream objectives
→ Create an environment of Continuous Improvement or Kaizen.
→ During the execution of the plan eliminate all wasteful activity from the system or process flow.

27. Step 5 – Align & Analysis of Current and Future
State:
→ Arrange analysis and alignment meeting
→ Periodic basis (based on action plan schedule)
→ Review event implementations & results
→ Evaluate the impact to value stream metrics (individual events and overall)
→ Review next quarter events
→ Inspect changes in a business environment
→ Communicate results
→ Update implementation plan as required
→ Address resistance and sustainment issues
Result Analysis - Current State Vs Future State
Sr No Description Current State Future State
1 Total Lead time 43 Min 34 Min
2 Value added time 8 Min 8 Min
3 Efficiency of total value chain 0,186 23,53%
4 Improvement in value chain efficiency ** 26,50%

28. Keys Points for Successful VSM Study:
→ Select the right person in the VSM project team.
→ Give specific decision-making authority to the team member for the successful project run.
→ All team members give their participants effectively and efficiently.
→ Always attack the process, Don't attack people
→ Frequently analyze the progress of the project and motivate people for a successful project.