Process Mapping and Value Stream Analysis

Operational Auditing and Quality Assurance October 25, 2025
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Introduction

This course provides practical training in the essential skills of process mapping and Value Stream Analysis (VSA), the foundational tools for any continuous improvement initiative. Participants will learn how to graphically represent current-state processes (Current State Map) to identify bottlenecks, waste, and non-value-added activities. The training covers the standard symbols, measurement techniques, and the steps required to develop a future, optimized state (Future State Map). Mastery of these tools is crucial for anyone responsible for improving efficiency, reducing cycle time, and creating a culture of Lean thinking within an organization.

Objectives

Upon completion of this course, participants will be able to:

  • Explain the importance of process mapping for process analysis and communication.
  • Create a clear, cross-functional process map (swimlane diagram).
  • Conduct a Value Stream Analysis (VSA) to identify the flow of materials and information.
  • Identify and quantify the seven (or eight) types of waste (Muda) within a value stream.
  • Measure key process metrics such as cycle time, lead time, and Process Cycle Efficiency (PCE).
  • Construct a Current State Map and a Future State Map of a value stream.
  • Develop an implementation plan to transition from the Current to the Future State.
  • Use VSA to prioritize improvement opportunities and set clear objectives.

Target Audience

  • Continuous Improvement Specialists and Lean Practitioners.
  • Process Engineers, Analysts, and Business Analysts.
  • Managers and Supervisors responsible for operational efficiency.
  • Project Team members involved in process redesign.
  • Quality and Operations personnel seeking to identify and eliminate waste.
  • Anyone requiring a visual tool for understanding complex business processes.

Methodology

  • Group Activities: Creating a Current State Map from a video case study.
  • Individual Exercises: Calculating Process Cycle Efficiency (PCE) from data.
  • Hands-on Simulation: Mapping a physical process using swimlanes and post-its.
  • Practical Application: Design of a Future State Map based on Lean principles.
  • Discussions on common process bottlenecks and information flow errors.

Personal Impact

  • Master the essential Lean tools of process and value stream mapping.
  • Develop a systematic method for visualizing and analyzing complex processes.
  • Improve ability to quantify waste and demonstrate the value of improvements.
  • Enhance communication of process problems and proposed solutions.
  • Increase personal value as a key contributor to Lean initiatives.
  • Gain confidence in identifying high-impact improvement opportunities.

Organizational Impact

  • Clear, unambiguous documentation of key operational processes.
  • Measurable reduction in process lead time and cycle time.
  • Efficient allocation of resources toward high-impact improvement projects.
  • Establishment of a data-driven baseline for continuous improvement.
  • A clearer understanding of information flow and its impact on the organization.
  • Accelerated deployment of Lean thinking and waste elimination culture.

Course Outline

Unit 1: Foundations of Process Mapping and Visualization

Section 1.1: Process Mapping Essentials
  • The role of process mapping in problem-solving and communication.
  • Introduction to different mapping levels (High-level SIPOC vs. Detailed Flowchart).
  • Standard mapping symbols (e.g., flowchart symbols, swimlanes).
  • Techniques for engaging stakeholders in accurate process documentation.

Unit 2: Introduction to Value Stream Analysis (VSA)

Section 2.1: VSA Concepts and Tools
  • Defining the Value Stream and its boundaries.
  • The difference between process mapping and Value Stream Mapping.
  • Identifying and quantifying the eight types of waste (DOWNTIME).
  • Understanding the flow of material and information.

Unit 3: Creating the Current State Map

Section 3.1: Data Collection and Mapping
  • The Gemba Walk: Going to the actual process to collect data.
  • Collecting essential data: cycle time, setup time, uptime, and inventory.
  • Graphically mapping the Current State of the value stream.
  • Calculating Process Cycle Efficiency (PCE) for the baseline.

Unit 4: Identifying Opportunities and Designing the Future State

Section 4.1: Analysis and Design Principles
  • Analyzing the Current State Map for bottlenecks and non-value-added time.
  • Introduction to Lean principles for Future State design (e.g., Takt Time, Pull Systems).
  • Developing the ideal Future State Map and calculating its projected PCE.
  • Using the seven flow questions to drive Future State design.

Unit 5: Implementation Planning and Sustaining the Gains

Section 5.1: Execution and Control
  • Developing a detailed implementation plan and roadmap.
  • Prioritizing the improvement opportunities based on impact and effort.
  • Defining metrics and developing a control plan to sustain the Future State.
  • Presenting the VSA findings and proposed roadmap to management.

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