Process Mapping and

Value Stream Mapping

Dr. S. Vinodh,
Department of Production Engineering
 Process mapping
• A process map is a visual representation of the process step by step
(in sequence)

• It serves as a tool in lean manufacturing to understand the current

status of the process in steps

• It helps the management to identify the steps in process which adds

value to the customer and those do not add any value.

• It is used to identify the boundaries of a process where the

measurements are important.

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Why to prepare process maps?
• Whenever an organization wants to understand a process, it is
necessary to prepare a process map depicting the entire sequence of
the process from beginning to end.

• It is also used to diagnose any problems existing in the process

• It can be used as a tool during training

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 Advantages of process mapping
• It helps to understand the current process and to identify the
improvement opportunities

• Process map identifies the actual paths revealing areas of risk and
potential solutions by communicating process related ideas,
information

• It makes the team to brainstorm each of the process steps, clearly

identify the wastes in the process and decide on the future process
map

• To clearly identify the improvement

• As a visual training aid to train the personnel in the improved process

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Types of process map
High-level process maps

• It gives a bird’s eye of the entire process.

• Provides only the major steps in the process

• It is the real starting point of any process study

• It helps to establish the scope of the process and identify the significant
issues

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High-level process map

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Detailed process maps
• It shows each and every step involved in the process

• It has a starting point and an ending point

• It indicates the input for each process and output from the process

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Detailed process map

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Constructing a process map
A process mapping team (PMT) has to be formed consisting of lean
leader, process owner and associated departments.

PMT should prepare the high level process map

1. Determine the boundaries- Starting and Ending points

2. List the steps – Various process steps must be written. Steps must be
short sentences which start with a verb

3. Sequence the steps – use post-it notes so as to move tasks

4. Draw appropriate symbols

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Constructing a process map
5. Draw process map using a computer

6. Check for completeness

7. Finalize the process map

8. Analyze the process map to identify the waste

9. Prepare the revised process map

10. Calculate the savings and publish

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Symbols used in Process
mapping

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Value Stream Mapping
• VSM is a tool to visually indicate all actions required to bring about a
product or service in logical steps from start to finish

• It shows all the actions required to complete a product or service

through to the customer

• The purpose of VSM is to understand the value flow

• VSM helps in understanding how the product flows from when the
customer orders to the dispatch of the product to the customer

• It helps to identify the steps that add value to the customer and do not
add value to the customer

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Value stream mapping
VSM graphically depicts the following:

1. Each process or activity

2. Inventory or queues between the steps

3. Set up times, cycle time

4. Timeline for the whole value stream

5. Information flow from customer through the production process

6. Picture of the complete process

7. Changes needed to be implemented

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 Steps to be followed while
preparing the VSM
1. Understand the current status and prepare the current state
mapping
2. Preparing the current state of the process helps in the following
I. Communication
II. Understand the existing state
III. View the work from the a process perspective
IV. Understand the magnitude of the change planned
V. Understand the tasks required to move from the current
process to a new process
VI. Ensure problems are not repeated
VII. Measure the new process on performance base line

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Preparing current state map
• A product or product family should be selected so that the task is
manageable

• Value stream map should not be drawn for multiple product lines

• Both material flow and information flow must be mapped

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STEPS:
I. Document customer information/Demand

II. Complete a quick walk through to identify the main processes

III. Map the basic production process

IV. Define the data to be collected

V. Collect and map the data

VI. Document supplier information

VII. Establish information flow

VIII. Identify where the material is being pushed

IX. Quantify production lead time versus processing time

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2. Collect the data
Cycle time(C/T): The time that elapses, in sec/min, between one part
coming off the process and the next part coming in.

Changeover time(C/O): The time to switch from producing one product

type to another
Available work time: the amount of work time available per shift in each
process

Up time: the amount of time the machine is running

Value added time: the time spent transforming the product in a way that
the customer is willing to pay for

Lead time: the time it takes for one piece to travel through the entire
value stream from start to finish

CD: customer demand in quantity per month

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Data collection
• Data collection must be taken in multiple shifts
• Collected data must be arranged in an information box

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3. ARRANGE data in an
information box

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4. CURRENT STATE MAPPING

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5. Analyze the map
• Identify which activities are “non-value adding”

• Understand customer requirement

• Recognize supplier capabilities and constraints

• Calculate the current inventory/WIP

• Compute the Takt time and determine what prevents us in producing

the same

• Make sure there is continuous flow and if possible make it as a single

piece flow

• Balance the line

• Make a future state drawing

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6. Future State Mapping

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Results- after implementing the
future state map
• The number of operations reduced from six to two

• Operators reduced from six to one

• Inventory reduced from 22 days to 7 days

• Space reduced by 60%

• Lead time is also reduced

• Quality improved since the operator is able to detect defects

immediately

• Supplier quality is also improved.

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THANK YOU

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