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The Seven Value Stream Mapping Tools Peter Hinesand Nick Rich IJOPM1997
The Seven Value Stream Mapping Tools Peter Hinesand Nick Rich IJOPM1997
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Introduction
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Work carried out in the first Supply Chain Development Programme (SCDP I),
together with early work in the second programme (SCDP II), has shown that in
order fully to understand the different value streams[1] in which the sponsors
operate, it is necessary to map these intercompany and intracompany value-
adding processes. These value-adding processes make the final product or
service more valuable to the end consumer than otherwise it would have been.
The difference between the traditional supply or value chain and the value
stream is that the former includes the complete activities of all the companies
involved, whereas the latter refers only to the specific parts of the firms that
actually add value to the specific product or service under consideration. As
such the value stream is a far more focused and contingent view of the value-
adding process.
At present, however, there is an ill-defined and ill-categorized toolkit with
which to understand the value stream, although several workers (e.g. [2-5]) have
developed individual tools. In general these authors have viewed their creations
as the answer, rather than as a part of the jigsaw. Moreover, these tools derive
from functional ghettos and so, on their own, do not fit well with the more cross-
functional toolbox required by today’s best companies. It is the purpose of this
paper to construct a typology or total jigsaw to allow for an effective
application of sub-sets of the complete suite of tools. The tools themselves can
then effectively be applied, singularly or in combination, contingently to the
requirements of the individual value stream.
along the value stream and lack of the tools appropriate to creating this
visibility. This paper aims to help researchers and practitioners remedy such
deficiencies. The waste terminology described above has been drawn from a
manufacturing environment, specifically from the automotive industry, and
from a Japanese perspective. As a result some translation of the general
terminology will be required to adapt it to a particular part of the value stream
and to particular industries in non-Japanese settings. Consequently, a
contingency approach is required to some extent.
Such an approach has been the subject of considerable previous work at the
Lean Enterprise Research Centre. This would include the application by
Hines[10] of the kyoryoku kai (supplier association) to a range of UK-based
industry sectors and the introduction by Jones[11] of the Toyota production
system philosophy to a warehouse environment. Jones has shown that the seven
wastes required rewording to fit an after-market distribution setting. He
therefore retitled the seven wastes as:
(1) faster-than-necessary pace;
(2) waiting;
(3) conveyance;
(4) processing;
(5) excess stock;
(6) unnecessary motion; and
(7) correction of mistakes.
50 Overproduction L M L M M
Waiting H H L M M
Transport H L
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Inappropriate
processing H M L L
Unnecessary
inventory M H M H M L
Unnecessary
motion H L
Defects L H
Overall
structure L L M L H M H
Table I. Notes: H =High correlation and usefulness
The seven stream M = Medium correlation and usefulness
mapping tools L = Low correlation and usefulness
and practitioners. Until now, however, there has been no decision support
mechanism to help choose the most appropriate tool or tools to use.
The tools themselves are drawn from a variety of origins as show in Table II.
These origins include engineering (tools 1 and 5), action research/logistics (tools
2 and 6) operations management (tool 3), and two that are new (tools 4 and 7).
As can be seen, they are generally from specific functional ghettos and so the
full range of tools will not be familiar to many researchers, although specific
tools may be well-known to individual readers. Each of these is reviewed in turn
before a discussion is undertaken of how they can be selected for use.
52
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Figure 1.
Users and non-users of
DFM
53
Main store
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Figure 2.
Supply chain response
matrix – a distribution
example
54
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Figure 3.
Production variety
funnel – a brewing
industry case
55
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Figure 4.
The quality filter
mapping approach – an
automotive example
Each of these three types of defect are then mapped latitudinally along the
supply chain. In the automotive example given (Figure 4), this supply chain is
seen to consist of distributor, assembler, first-tier supplier, second-tier supplier,
third-tier supplier and raw material source. This approach has clear advantages
in identifying where defects are occurring and hence in identifying problems,
inefficiencies and wasted effort. This information can then be used for
subsequent improvement activity.
Pallets
180
160
140
120
100
80
60
40
20
0
28.8.93
25.9.93
23.10.93
20.11.93
18.12.93
15.1.94
12.2.94
12.3.94
09.4.94
07.5.94
04.6.94
02.7.94
30.7.94
27.8.94
24.9.94
22.10.94
19.11.94
17.12.94
Figure 5.
Weeks
Demand amplification Retail sales
mapping – an FMCG Orders on Suppliers
food product sample
Source: [11]
up dual-mode solutions where regular demand can be managed in one way and The seven value
exceptional or promotional demand can be managed in a separate way[20]. stream mapping
tools
Decision point analysis
Decision point analysis is of particular use for “T” plants or for supply chains
that exhibit similar features, although it may be used in other industries. The
decision point is the point in the supply chain where actual demand pull gives 57
way to forecast-driven push. In other words, it is the point at which products
stop being made according to actual demand and instead are made against
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Stores
Factory
Suppliers National Regional
Distribution Distribution
Purchased Work in Finished Centre Centre
Goods progress Good
Make To Order
Gaining an understanding of where this point lies is useful for two reasons:
(1) In terms of the present, with this knowledge it is possible to assess the
processes that operate both downstream and upstream from this point.
The purpose of this is to ensure that they are aligned with the relevant
pull or push philosophy.
(2) From the long-term perspective, it is possible to design various “what if”
scenarios to view the operation of the value stream if the decision point
is moved. This may allow for a better design of the value stream itself.
IJOPM Physical structure
17,1 Physical structure mapping is a new tool which has been found to be useful in
understanding what a particular supply chain looks like at an overview or
industry level. This knowledge is helpful in appreciating what the industry
looks like, understanding how it operates and, in particular, in directing
attention to areas that may not be receiving sufficient developmental attention.
58 The tool is illustrated in Figure 7 and can be seen to be split into two parts,
namely: volume structure and cost structure. The first diagram (Figure 7(a))
shows the structure of the industry according to the various tiers that exist in
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both the supplier area and the distribution area, with the assembler located at
the middle point. In this simple example, there are three supplier tiers as well as
three mirrored distribution tiers. In addition, the supplier area is seen to include
raw material sources and other support suppliers (such as tooling, capital
equipment and consumable firms). These two sets of firms are not given a tier
level as they can be seen to interact with the assembler as well as with the other
supplier tiers.
Figure 7.
Physical structure
mapping – an
automotive industry
example
The use of this toolkit at this stage should not be confined to any particular
theoretical approach to ultimate implementation. Thus the options can be left
open at this stage over whether to adopt a kaizen or business process re-
engineering approach once the tools have been used[25,26]. It is the authors’
belief that the framework does not constrain this choice process.
60
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Figure 8.
Using the VALSAT
approach to select
effective value stream
mapping tools
think about which of their competitors is best at reducing particular wastes and
managing their complete supply/distribution chain. This knowledge may then
lead on to more formal benchmarking with these companies, if this is felt to be
appropriate, or at least a good focus for subsequent mapping activities.
The next stage (E), therefore, is to ascertain the individual importance
weighting of the seven wastes and the overall industry structure. This is
achieved most effectively by allocating a total of 40 points for the eight factors
and asking the interviewee to apportion these on the basis of an importance
rating between the factors, with the proviso that no one factor can attract more
than ten points. If there is more than one interviewee, then the different scores
may be aggregated and rebased to total 40 points.
The last arithmetical stage of this approach is to create total weights for each
tool. In effect, what is being done here is to give a rating to each tool in terms of
how useful it is in identifying the various wastes designated as of most
importance by the organization or organizations. This is achieved by giving
each of the different correlations given in Table I a score. Thus, high
correlations are equivalent to nine points; medium three points; and low, to a
single point. Then, for each correlation, a total importance score is calculated.
This is achieved by multiplying the weighting of each waste/structure by the
correlations. Thus, referring to the correlations in Table I, if the weighting for
overproduction is six points the usefulness of the tools in addressing
overproduction will be:
• six for process activity mapping (6 × 1); The seven value
• 18 for supply chain response matrix (6 × 3); stream mapping
• zero for production variety funnel (6 × 0); tools
• six for quality filter mapping (6 × 1);
• 18 for demand amplification mapping (6 × 3);
61
• 18 for decision point analysis (6 × 3); and
• zero for physical structure mapping (6 × 0).
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This type of calculation is then applied to each of the other rows so that scores
are recorded for each individual correlation. Once this is complete the total
scores for each column are then summed and recorded in the total weight
section, or “F” in Figure 8. The columns which have the highest scores are those
that contain the most appropriate tools. As a rule of thumb it is useful to choose
more than one tool. Indeed, as a final check, the more important two or three
wastes/structure should have been addressed by tools with which they are
highly correlated or failing this by at least two tools with which they have a
medium correlation. This will ensure that each waste/structure is covered
adequately in the mapping process.
This section therefore will have assisted the reader to identify which tool or
tools to use. However, once the tools have been run it may be that some
unexpectedly high wastes have become apparent. For instance, the demand
amplification mapping tool may have been employed to identify unnecessary
inventory and waiting. However, as the tool also has a medium correlation with
overproduction, it will be useful in identifying such waste if it exists but was
not recognized at first by the managers involved. This backflushing may
therefore identify some unanticipated but potential improvement areas and,
hence, lead to some breakthroughs.
After this mapping process is complete, the researcher will be able to use
each individual tool with its associated benefits to undertake more detailed
analysis of the value stream with a view to its improvement. As stated above, it
is not the purpose of this paper to convert other researchers to a kaizen or
business process re-engineering approach in this subsequent work. However,
the various mapping tools described will help with whichever approach is
chosen. In general, the removal of non-value adding waste is best done using a
kaizen approach, whereas the removal of necessary but non-value adding waste
requires a more revolutionary strategy wherein the application of business
process re-engineering may be more appropriate.
Case example
For the reader to gain a better understanding of the approach, a brief case
example will be reviewed. The company involved is a highly profitable leading
industrial distributor with over 60,000 products and an enviable record for
customer service.
IJOPM After undertaking preliminary discussions it was decided to focus on the
17,1 upstream value stream to the point at which goods are available for distribution
by the firm. Nine products were chosen based on a Pareto analysis from one
particular value stream, namely: the lighting product range. Within this range,
interviews with key cross-functional staff showed that unnecessary inventory,
defects, inappropriate processing and transport were the most serious wastes in
62 the system. In order to understand this in more detail, and using the mapping
correlation matrix (Table I), it was decided to adopt five of the tools:
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