Value Stream Mapping for Manufacturing


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 your colleagues around the world.

The value stream map 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.

Mapping is a critical initial step in lean conversions 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.

This workshop can be run as a one day introduction to Value stream mapping and improvement, or as a two or three day practical workshop taking one of your value streams, identifying improvements and developing an implementation plan to be completed within a 90 day period.

We use the “Training to See” package developed by John Shook for Lean Enterprise Institute. Delegates will conduct a series of exercises so that they are able to translate how the tool can be used in their environment – be it high volume repetitive manufacturing or bespoke made to order products/services.

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
  • Value Stream Maps in a non-manufacturing setting

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?

  • Operators, engineers, managers, supervisors, technical support personnel and change agents
  • Any industry with multi-step processes
  • Organisations 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. Both books can be ordered from Lean Enterprise Australia at our bookstore.