Lean Manufacturing:
Value Stream Mapping

Streamline Your Work Processes to Reduce Lead Time and Costs

Using Catalyst Connection’s Value Stream Mapping process, you can create a map of the material and information flow associated with one of your products or product families. This practical, yet powerful tool, enables you to identify and document the flow of materials, product and information in your process from order entry and raw materials, through production, to delivery of finished goods to your customers.

Mapping the value stream begins with a current state map that documents existing conditions. A benchmark for future measurement of improvements, this map also helps you recognize inefficiencies and waste that prevent efficient flow throughout your operations and contribute to higher costs and longer lead times. Equipped with this system-wide view of the value stream, you can begin to apply lean manufacturing techniques to diagnose sources of waste, inefficiency and non-value added efforts and create a future state map.

The future state map depicts your vision for an efficient, lean value stream that is smoother, more efficient in material and information flow, more flexible and more responsive to customers’ demands. Through brainstorming and the application of lean manufacturing techniques, the Value Stream Mapping process enables your team to create an action plan for prioritizing and managing the improvements necessary to achieve the vision you’ve described in your future state map.

Specifically, your team will learn to:

• Recognize waste as a symptom
• Distinguish between process efficiency and value-stream efficiency
• Produce to customer demand
• Create continuous flow
• Create "pull" where "flow" is not possible
• Simplify scheduling

Results

Clients who have used Value Stream Mapping to transform their operation into a Lean operation have discovered how to produce more from their existing resources. Implementing the improvements necessary to achieve the future state they defined through the mapping process, Catalyst Connection clients have succeeded in:

• Increasing capacity and productivity
• Reducing overall lead times
• Reducing costs
• Improving cash flow and business liquidity by reducing excess work-in-process and other inventories
• Increasing sales and profits as a result of streamlining their operations
• Increasing customer satisfaction by improving delivery performance and reducing quoted lead times

CONTACT: F. Tracy Alim, Vice President,Consulting, 412.918.4284