Value Stream Mapping and Kaizen Success Stories

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Value Stream Mapping was used at a large textile facility to identify opportunities for improvement of their basic product line. The plan (developed to reach a clearly defined future state) resulted in several Kaizen events that have thus far resulted in the following improvements: lead time (4 to 3 weeks), waste (4% to 2%), change-over times (4 to 2 hours and 4 to 3 hours), and on-time deliveries (93% to >98%). Improvements made at this facility have prompted the corporation to adopt Lean principles at all of their facilities.

After training all 36 employees in Lean Principles at a production facility, two Kaizen events were conducted to address work flow constraints. The events effectively used spaghetti diagrams, process maps, etc. to identify constraints and guide improvements. The first Kaizen included the rearrangement of two storage shelves and three work stations for a step level improvement in productivity and reduction of lead times from 3-5 weeks to 1-3 weeks. The second Kaizen event focused on improving the utilization of a constraining piece of equipment from 25% to >50%.

Value Stream Mapping was used to plan a transfer of a process from one department to another. Problem areas were identified in the current state map and corrected in the future state map used for the new layout in the new building. This exercise along with the training of all employees (500+) in Lean Principles are credited for keeping this facility in operation during a timeframe of corporate cutbacks.

Value Stream Mapping was used to improve the order entry and accounts payable information flow in an expanding company of 100+ employees. Cycle times were predicted to be reduced 75% upon successful implementation of the action plans developed to achieve the future state maps.

A Kaizen Event was conducted to improve productivity in a constrained production department from 58% to > 68% uptime. Successful implementation of the 14 action plans is expected to avoid cost outlays of $500k and save $250k/year. This Kaizen event followed training of all 60 employees in Lean Principles and Problem Solving.