Books

Value Stream Management: Eight Steps to Planning, Mapping, and Sustaining Lean Improvements

Don Tapping, Tom Luyster, and Tom Shuker

New York, New York: Productivity, Inc., 2002

The authors of this book have provided a well-written and well-organized book on implementing lean production. They state that "If you hope to create an authentic lean enterprise, rather than a superficial one, you must learn the tools and methods of lean and how to integrate them. What is needed is a complete process that links strategic plans to daily work while at the same time teaching the fundamentals. The eight steps of Value Stream Management, followed sequentially, is that process." Each chapter of the book focuses on one of the eight steps of the Value Stream Management process. The eight steps are:

1. Commit to Lean—The four primary components of doing this are (a) Identify the Value Stream manager/champion and core implementation team members; (b) Kick off the Value Stream Management project; (c) Managers go to the shop floor and observe production first-hand; and (d) Review the proposals of the core implementation team. The book provides a management commitment checklist to identify how the management can show its commitment to lean;
2. Choose the Value Stream—The three common methods to define the Value Streams are (a) the customer defines the value stream; (b) use product-quantity (PQ) analysis; or (c) use product-routing analysis. The authors of the book suggest three rules of thumb on how to select which value stream to work on;
3. Learn About Lean—This chapter discusses the cost reduction principle, the seven deadly wastes, just-in-time production, jidoka, the 5S system, visual workplace, and the three stages of lean application (demand, flow, and leveling);
4. Map the Current State—This chapter explains how to prepare for and execute value stream mapping;
5. Identify Lean Metrics—This chapter provides a list of lean metrics, as well as identifying specific lean metrics in your organization;
6. Map the Future State—This process takes place in three stages: understanding customer demand, implementing continuous flow, and leveling work;
7. Create Kaizen Plans—The authors recommend that one should review the future-state map and create a monthly kaizen plan, determine milestones for each major kaizen activity, complete a Value Stream Management story board, and obtain management approval for kaizen plans through "catchball;"
8. Implement Kaizen Plans—Some suggestions here are (a) communicate, communicate, communicate; (b) address negative behavior early in the implementation; (c) do not let a problem stop the process; (d) consider each kaizen event as an experiment; (e) reward and recognize people's efforts, practice mutual trust and respect, and treat people with honesty and integrity every day; (f) be present; and (g) be flexible.

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