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MASTERING VALUE STREAM MAPPING:



UNLOCKING EFFICIENCY AND EXCELLENCE


Duration: 8 hours

Program Overview



Value Stream Mapping (VSM) is a powerful tool at the core of Lean improvement strategies, designed to streamline processes, reduce lead times, and expedite time-to-market. By visualizing the entire value stream, VSM exposes inefficiencies and wastes that disrupt the flow of products and resources, ultimately affecting the value chain and leading to underutilization of manufacturing capacity. While VSM focuses on the flow of materials and information, it intentionally excludes individual performance, focusing solely on process optimization and system improvements.


This program is designed to equip participants with the essential knowledge and practical techniques to "see the flow" of materials and information within their current state. By learning to identify roadblocks and inefficiencies, participants will gain the ability to pinpoint disruptions that slow down the overall process and hinder optimal performance. The goal is to help professionals recognize where value is being added and where waste is occurring, ultimately enabling better decision-making to enhance efficiency.


VSM serves as a crucial starting point for various stakeholders, including management, engineers, and production associates, to recognize and address waste within their processes. The insights gained through VSM highlight the gaps between the current state and the desired future state, offering a clear roadmap for reaching organizational goals. These goals might include reducing lead times, improving workflow balance, minimizing space requirements, and decreasing Work In Progress (WIP).


In essence, VSM provides a holistic view of the process, capturing all actions—both value-added and non-value-added—that are required to move a product from raw materials receipt to final delivery. The tool helps teams design a new, more efficient path by eliminating waste, improving flow, and aligning efforts with the organization's core objectives for continuous improvement. By the end of the program, participants will be equipped to lead VSM initiatives and create actionable plans that drive meaningful improvements across manufacturing operations.


Target Audience

  • Operations & Production Leaders
  • Process Improvement & Lean Practitioners
  • Industrial & Manufacturing Engineers
  • Supply Chain & Logistics Professionals
  • Supervisors & Team Leads
  • Quality Assurance & Continuous Improvement Teams
  • Executives & Decision-Makers



Program Outline



Session 1: Introduction to Value Stream Mapping

  1. Definition and purpose of Value Stream Mapping.
  2. Importance of VSM in identifying value and waste in processes.
  3. Understanding value-added vs. non-value-added activities.
  4. Introduction to lean principles and their relation to VSM.
  5. Explanation of standard symbols used in VSM diagrams.


Session 2: Mapping the Current State

  1. Selecting the process or product family to map.
  2. Defining process boundaries and key metrics.
  3. Step-by-step guide to mapping the current process flow.
  4. Identifying process steps, information flow, and material flow.
  5. Calculating takt time, cycle time, and lead time.


Session 3: Designing the Future State

  1. Analyzing the Current State: Identifying bottlenecks, waste, and inefficiencies.
  2. Creating the Future State Map: Techniques to streamline processes and reduce waste.
  3. Setting goals for flow improvement and lead time reduction.
  4. Prioritizing improvements based on impact and feasibility.
  5. Exercise: Participants design a future state map using the provided scenario.


Session 4: Implementation Planning and Wrap-Up

  1. Developing an Improvement Plan for implementing changes.
  2. Drawing the map of the future state illustrating Kaizen initiatives
  3. Involving teams and stakeholders in the improvement process.
  4. Recap of key concepts and techniques.
  5. Open discussion on applying VSM to real-world challenges.


Program Outcomes



By the end of the training, participants will:

  1. Gain a foundational understanding of VSM and its applications.
  2. Create a Current State Map
  3. Learn how to map a process flow accurately, including material and information flows.
  4. Identify key metrics such as cycle time, lead time, and takt time.
  5. Design a Future State Map
  6. Gain the ability to analyze current state maps,
  7. identify bottlenecks and inefficiencies, and propose solutions.
  8. Design an optimized future state map to improve flow, reduce waste, and enhance performance.
  9. Implement Actionable Plans
  10. Develop a practical roadmap for implementing improvements based on the future state map.
  11. Prioritize actions for maximum impact on process performance and efficiency.
  12. Learn techniques for monitoring and sustaining improvements over time.
  13. Understand how to foster a culture of continuous improvement within teams and across the organization.
  14. Apply VSM in Real-World Scenarios
  15. Be prepared to use VSM techniques to map and improve their own organizational processes.
  16. Build confidence in leading VSM workshops and guiding teams toward process optimization.


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