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Value Stream Mapping Fundamentals: Seeing & Improving the Flow of Value

This course introduces professionals to the foundational practice of Value Stream Mapping (VSM)—a cornerstone of Lean thinking. VSM is more than a diagramming exercise; it is a way to see how value flows (or fails to flow) through an organization. Whether in manufacturing, healthcare, or administrative settings, organizations often struggle with hidden inefficiencies, delays, and waste. By learning to map, analyze, and redesign value streams, participants gain the skills to unlock speed, quality, and customer value in their processes.

Through a structured six-module program, learners will progress from understanding the basics of Lean and value streams to building their own current state maps, spotting waste, envisioning improved future states, and developing actionable improvement plans. The course closes by expanding the view to extended value streams—spanning suppliers, customers, and enterprise-wide collaboration—equipping learners to apply VSM at every level.

By the end of this course, participants will be prepared to lead or contribute to Lean transformation initiatives with confidence, clarity, and practical tools.

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Modules Overview

Module 1: Introduction to Value Stream Thinking

  • Objective: Build foundational understanding of value streams, Lean thinking, and the purpose of VSM.

  • Highlights:

    • What a value stream is and how it differs from individual processes.

    • Lean principles: value, waste (muda), flow, pull, and perfection.

    • Why mapping reveals opportunities invisible in day-to-day work.

    • Key terms such as lead time, cycle time, takt time, and value-added vs. non-value-added.

    • Real-world examples from both factory floors and office environments.

    • Review of the three core texts that shaped VSM practice.

  • Key Takeaway: Participants grasp why VSM is central to Lean transformation and continuous improvement.

Module 2: Understanding the Current State Map

  • Objective: Learn how to observe and map the current state of a value stream.

  • Highlights:

    • Role of the current state map in “making the invisible visible.”

    • Preparing for mapping: defining scope and selecting product/service families.

    • Conducting a Gemba walk to capture how value is really created.

    • Collecting critical data: steps, information flows, timings, and inventory.

    • Basic VSM symbols and notation.

    • Sample walkthrough of a current state map.

    • Interactive Exercise: Participants practice building a simple map from a case example.

  • Key Takeaway: Participants can collect process data and create a baseline current state map.

Module 3: Seeing the Waste (Muda) in the Value Stream

  • Objective: Develop the ability to analyze and identify different types of waste.

  • Highlights:

    • The 7+1 wastes of Lean and how they manifest.

    • Recognizing waste in manufacturing vs. administrative processes.

    • Spotting bottlenecks, rework loops, overproduction, and hidden wastes like excessive emails or approvals.

    • Using VA/NVA analysis and time metrics to expose inefficiencies.

    • Examples of successful waste elimination.

  • Key Takeaway: Participants learn to spot and categorize waste in value stream maps.

Module 4: Designing the Future State Map

  • Objective: Create a future state map that enhances flow and reduces waste.

  • Highlights:

    • Guiding questions: customer needs, flow, pull, workload leveling.

    • Lean flow enablers: takt time, supermarkets, FIFO lanes, pacemaker processes.

    • Future state symbols and how they differ from current state maps.

    • Contrasting office and manufacturing examples of future state design.

    • Generating improvement ideas: layout changes, systems upgrades, and role clarification.

    • Interactive Exercise: Build a future state map from a simplified case study.

  • Key Takeaway: Participants understand how to transform current state analysis into future state design.

Module 5: From Map to Action – Implementation Planning

  • Objective: Translate future state designs into actionable improvement plans.

  • Highlights:

    • Creating a value stream improvement (Kaizen) plan.

    • Prioritizing improvements with impact vs. effort analysis.

    • Defining roles, responsibilities, and timelines.

    • Using metrics such as lead time reduction to track progress.

    • Sustaining gains through standard work, visual management, and Lean leadership.

    • Practical tips for administrative and office settings.

  • Key Takeaway: Participants can convert future state maps into structured improvement plans.

Module 6: Mapping Beyond the Enterprise – The Extended Value Stream

  • Objective: Explore VSM across organizational boundaries and continuous improvement cycles.

  • Highlights:

    • Extended value streams: supplier–organization–customer.

    • Understanding systemic waste vs. local optimization.

    • Building cross-boundary collaboration.

    • Case studies from automotive, healthcare, and service industries.

    • Governance and councils to sustain enterprise-wide improvement.

    • Digital VSM and tools for remote collaboration.

    • Wrap-up with review, resources, and a self-assessment.

  • Key Takeaway: Participants gain perspective on applying VSM at a larger system level.

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Capstone Project: End-to-End Value Stream Mapping & Improvement Plan

Project Overview

Learners will apply all six modules of training by selecting (or being assigned) a process to analyze, map, and improve. This process can be real (from their workplace) or simulated (provided case study). By the end, each learner/team will deliver a comprehensive VSM package: a current state map, waste analysis, future state map, and an implementation plan.

The project demonstrates mastery of VSM fundamentals and provides a tangible artifact they can use in their organizations.

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