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 Duration 14 hours

Course Outline

Foundations of Value Stream Mapping

  • Core Lean principles and the strategic application of VSM
  • Essential definitions: value-adding activities, non-value-adding tasks, takt time, lead time, and process cycle efficiency
  • Standardized VSM notation and visual conventions

Scope Definition and Value Stream Selection

  • Selection of specific products, components, or families for analysis
  • Establishing process boundaries and engaging relevant stakeholders
  • Collection of baseline performance data and operational metrics

Current State Process Mapping

  • Process observation: data collection methodologies and field assessment techniques
  • Documentation of process steps, material flows, inventory levels, and information exchanges
  • Calculation of operational metrics: cycle time, changeover duration, uptime, and idle time

Identification and Analysis of Waste

  • Categorization of the seven wastes and other non-value-adding activities
  • Methods for measuring the effect of waste on lead time and operational costs
  • Strategic prioritization to address high-impact inefficiencies

Future State Process Design

  • Principles for optimizing flow: pull systems, takt alignment, and level loading
  • Re-calculation of times and projected performance outcomes post-improvement
  • Visualization of future-state maps and establishment of performance targets

Execution Planning and Implementation Strategy

  • Translating future-state objectives into specific Kaizen events and project initiatives
  • Assignment of responsibilities, timelines, key performance indicators, and verification protocols
  • Change management strategies and mechanisms for sustaining improvements

Verification, Measurement, and Continuous Improvement

  • Establishment of monitoring dashboards and standard measurement procedures
  • Conducting pilot implementations and documenting lessons learned
  • Iterative VSM cycles and ongoing process refinement

Conclusion and Recommended Next Steps

Requirements

  • Basic understanding of process and workflow concepts
  • Experience with operational or administrative processes
  • Familiarity with performance metrics such as cycle time and lead time

Target Audience

  • Process improvement professionals
  • Operations managers and team leaders
  • Members of continuous improvement and Lean teams

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