Value Stream Mapping - A Foundation for Productivity Improvement

Value Stream Mapping (VSM) is one of the most effective ways to understand how work truly flows through a manufacturing organisation. It helps leaders and teams see the complete picture - the processes, delays, bottlenecks and handovers that affect performance.

As part of the Productivity Partnership, VSM is a core activity during Step 3: Productivity Deployment, giving organisations absolute clarity on where productivity gains can be unlocked.

Why VSM Matters for Manufacturing

Every site has hidden inefficiencies: waiting time, rework, inventory build-ups, approvals, transport and over-processing. These issues are often difficult to see when teams work in silos or focus on isolated steps.VSM solves this by providing:

• A visual end-to-end view of your process

• Clear identification of waste and constraints

• A common language for cross-functional teams

• Alignment on where improvement will have the highest impact

• A data-driven baseline to measure future progressThis makes VSM a powerful catalyst for productivity improvement.

How We Approach Value Stream Mapping

Our method is structured, inclusive and practical. We focus on understanding reality, not assumptions, through:

• Cross-functional workshops that bring operations, engineering, planning, quality and support teams together

• Walk-throughs and observation at each stage of the process

• Mapping current state, capturing cycle times, changeovers, inventory, delays and information flows

• Identifying waste and bottlenecks using simple, clear analysis tools

• Designing the future state, with improved flow, reduced lead time and stronger stability

• Prioritising actions that align to your 12-month Productivity PlanThe result is a shared blueprint for improvement, backed by data and owned by the team.

The Power of VSM During Deployment

When organisations move into Step 3, they need clarity on where to focus their effort. VSM provides that clarity. It strengthens deployment by:

• Highlighting critical constraints that limit output

• Helping teams prioritise improvements based on impact

• Linking waste reduction to measurable productivity gains

• Creating alignment across functions and shifts

• Providing a clear, visual tool for coaching and problem solvingWith a strong VSM in place, improvement activity becomes more targeted and more effective.

Practical Actions to Get Started

Manufacturing teams can build momentum quickly by:

• Selecting a product family or process area that matters most to customers

• Forming a cross-functional team who own the process end-to-end

• Walking the flow together and capturing real data

• Mapping the current state before jumping to solutions

• Identifying changes that reduce waste, variation and lead time

• Using simple visuals to communicate findings across the siteA well-facilitated mapping session often unlocks insights within hours.

Conclusion

Value Stream Mapping is a cornerstone of effective productivity improvement. By helping organisations see the whole picture, it becomes far easier to target the right problems, align teams and accelerate performance. As part of the Productivity Partnership, VSM plays a central role in Step 3 – enabling manufacturers to deliver measurable, sustainable improvements.

Clarity drives action and VSM provides that clarity.