See the Flow Before Fixing a Step
Use a value stream map to separate local busyness from end-to-end flow constraints.
A value stream map turns a busy factory into a timed system. Start With One Product Family Pick one product family with a shared routing and a real customer promise. If you mix products with different routes, the map becomes a mural instead of a decision tool. Walk the actual route, record the process time, changeover time, queue time, inventory count, and information trigger at each step. Do not start in a conference room; the value is in what the floor is actually doing. Separate Process Time From Waiting Time Most factories discover that value-added time is tiny compared with…
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