Step 4 in Value Stream Mapping

Create and Execute an Action Plan

An action plan is the method for transforming the process from its current state to the future state. This can be accomplished by using a combination of any of the six sigma methodology associated with best practices, and the appropriate tools from The Lean Toolkit. The action plan for this process resulted in dramatic improvement, ultimately reducing the lead-time to the customer from 8 weeks to 5 days. This was accomplished in a number of ways, beginning with the implementation of a Kanban system at the raw material sub-supplier. Waste was minimized in the manufacturing process in three ways: 1) Elimination of inspection by placing quality responsibility at the source, 2) Removing queue time by changing the flow from a push, to a pull process, and 3) Reducing the number of steps in each process. A summary of the dramatic results is shown in the attached figure. As the cycle repeats, further improvement could be achieved by implementing a Kanban system at the other end of the process; delivery of product to the customer.