3 Potential Hazards of Implementing Value Stream Mapping

Value stream mapping (VSM) was introduced atHowever, an observer may continue following the
Toyota as a method for investigating production andpreparer as he or she cleans the espresso machine.
design flows. The approach focused upon the mannerDoing so damages the accuracy of the VS map and
in which materials and information flowed throughout atherefore, prevents the proposal of an accurate Future
process to eventually yield value to an end customer.State.
Its goal was to help managers identify and eliminate#3 - VS Mapping Without Observation
waste. In doing so, they could reduce the costs ofMore than ever, companies maintain detailed records
production and lead times while improving customeron computer regarding every process on which they
satisfaction.rely. For example, a manufacturing plant might have
Originally, the methodology was used exclusively inrecords detailing the amount of time required to
lean manufacturing environments. Today, the disciplinetransport, package, or unpack items within a
is implemented within organizations in a variety ofwarehouse. The danger here is that the observer may
industries. This article will assume the reader has abe tempted to construct a VS map from these
basic understanding of the system through which valuerecords rather than actually taking the time to observe
stream mapping is implemented. Instead, we'll explorethe process. In many cases, the recorded details may
three potential hazards associated with itsfail to take every factor into account.
implementation.For example, a manufacturing plant might maintain that
#1 - Lack Of A Repeating Systema warehouse employee can transport an item from
VSM uses maps to follow resources through anthe delivery section of the facility to the packaging
iterative design. That is, there must be an identifiablearea in 4 minutes. A VSM observer might rely upon
process that repeats in order that the VS map canthat metric rather than visiting the warehouse to watch
accurately determine controls. It is through thatthe transaction occur. In reality, due to phone calls and
determination that sources of waste are isolated.sporadic stops, the employee may actually require 17
Many organizations apply VS mapping to businessminutes to transport the item. Unless observed, that
processes which fail to meet that standard. In somewaste would not be identified.
cases, the inputs vary along the way and as a result,Accuracy Follows Proper Implementation
identifying a repeating control is impossible. If a controlValue stream mapping is an effective methodology for
cannot be identified, a Future State cannot beuncovering waste in production and design flows. But,
proposed with a reasonable level of expectation.like other methodologies (i.e. Six Sigma, BPM, etc.), it
#2 - Following Human Inputsmust be implemented carefully. Controls must be
One of the most common mistakes made whenproperly identified and followed. Observers must be
performing value stream mapping is that the observerable to accurately determine when an observation
will mistakenly follow human inputs rather than theends (rather than continuing to follow human inputs).
control. For example, consider your local coffee shopAnd of course, VS mapping requires actual
and suppose the process under study is the creationobservation of processes rather than a reliance on
of a latte. A customer enters the shop and orders therecorded "standards." If these rules are not followed,
latte, thereby starting the observation. The studyan accurate Future State map that addresses existing
concludes once the latte is delivered to the customer.waste cannot be proposed.