High-level value-stream mapping

Learning objectives

• Draw a Define-stage value-stream map for one product family.
• Separate lead time from touch time.
• Identify a project-sized opportunity without designing solutions yet.

High-level, not detailed

Record customer demand, major processes, inventory/WIP, uptime, cycle time, changeover, yield, information flow and the total timeline. Detailed process mapping comes later in Measure.

Garment-factory example

Order-to-shipment mapping exposes waiting for lab dip, fabric approval, marker release, wash shade decision and final audit as the largest lead-time contributors.

Method

1. Walk the actual flow with typical data.
2. Draw material and information paths.
3. Calculate lead time and touch time.
4. Identify one project-sized opportunity.

Common mistakes

• Mapping from SOPs instead of the shop floor.
• Turning every Kaizen burst into the same project.