A value stream map (VSM) is a one-page picture of everything that happens from customer order to delivery — the process steps, the inventory between them and the information that controls them. It shows how long the whole flow takes and how little of that time adds value.
Step 1: Choose a product family
Map one family of products or services that share similar steps. Trying to map everything at once produces a map nobody can use.
Step 2: Walk the process
Walk the flow yourself, from shipping back to receiving. Record cycle time, changeover time, uptime, number of operators and inventory at each step.
Step 3: Draw the current state
- Process boxes with their data
- Inventory triangles between steps
- Information flows from customer to scheduling to the floor
- A timeline comparing lead time with value-added time
Step 4: Design the future state
Ask: where can we create continuous flow? Where do we need supermarkets and pull? Which single point should be scheduled? What improvements are needed to make this possible?
Step 5: Plan the implementation
Turn the future state into a list of Kaizen events and projects with owners and dates, and review progress monthly.
