Value Stream Mapping (VSM)
Combine material flow, information flow, inventory, process data and timeline to understand end-to-end lead time and design a realistic future state.
Purpose and method
Map material and information flow from customer demand through production and delivery.
When to use it
Use VSM to expose lead time, inventory, waiting, information delays and the difference between value-added and non-value-added time.
Core principle
VSM follows one product family from customer demand upstream through the value stream. It optimises flow across processes, not isolated local efficiency.
What the interactive module provides
- Current-state value stream
- Lead-time timeline
- Future-state improvement priorities
- current-state VSM, timeline, bottleneck and waste insights, future-state design priorities
Professional verification: The module supports learning, analysis and documentation. Verify results against actual process conditions, internal standards, safety requirements and competent professional judgement before implementation.
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Recommended workflow
Combine material flow, information flow, inventory, process data and timeline to understand end-to-end lead time and design a realistic future state.
- 1
Select one product family and customer demand
- 2
Walk the stream from shipping upstream
- 3
Capture process boxes, inventory and information signals
- 4
Calculate timeline, takt and flow barriers
- 5
Design future flow, pull and pacemaker actions
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Practical example
A product needs 38 minutes of processing but spends 12 days in the plant. The current-state map identifies two inventory supermarkets and a weekly planning batch as the main lead-time drivers.
Calculation or verification principle
Lead time is the sum of waiting and processing across the stream. Process cycle efficiency = total value-added time ÷ total lead time × 100%.
Required inputs → Expected outputs
- Required inputs
- product family, customer demand, process cycle times, changeovers, uptime, inventory, staffing and information triggers
- Expected outputs
- current-state VSM, timeline, bottleneck and waste insights, future-state design priorities
03
Common mistakes to avoid
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Mapping several unrelated product families together
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Drawing from meeting-room assumptions
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Focusing only on material and ignoring information
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Creating an ideal future state without an implementation plan
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Frequently asked questions
What data do I need to use this tool?
Prepare product family, customer demand, process cycle times, changeovers, uptime, inventory, staffing and information triggers.
What result does the module produce?
The module produces current-state VSM, timeline, bottleneck and waste insights, future-state design priorities.
Can I implement the result without further review?
No. Treat the output as a structured engineering and improvement aid. Verify source data, assumptions, safety, quality, legal requirements and local process conditions with competent responsible people before implementation.
LEAN Toolbox
Open interactive tool →Value Stream Mapping (VSM)
Combine material flow, information flow, inventory, process data and timeline to understand end-to-end lead time and design a realistic future state.