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Lean initiatives can be implemented in a series of Plan-Do-Study-Act (PDSA) cycles. In addition to the value stream map metrics, is important to keep a set of metrics to measure progress so that lean and quality objectives are tracked after each cycle. Here is an example of a PDSA outline:

Plan

• • Draw current value stream (VS) map in terms of processes (or activities) OR use future map from previous cycle

• • Calculate times for current VS map

• • Analyze current VS map for waste (delays, additional inspections, extra motions, transport, search time, etc)

• • Make a list of relevant, comparable metrics (Cost of non-conformance, delays, search times, inspection times, quality levels, delivery times, customer feedback)

• • List opportunities for removing such waste by reducing, re-organizing, realigning, training

• • Select easiest opportunities to implement with highest impact first

• • Draw future map based on selected opportunities

Do

• • Prepare action plan for selected opportunities

• • Implement plan by assigning tasks / due dates (no delays)

• • After implementation, let the system run and stabilize

• • Collect data again for measuring progress

Study

• • Analyze data and compare against the “before” set of metrics listed under the Plan phase

• • Provide visuals (charts / figures) to show progress / improvement

Act

• • Update future value stream (this will become the new “current” value stream)

• • List of things you’ve learned from this cycle? Implement in other areas and document for availability and easy access.

• • Goals achieved? If yes, What’s next on the opportunities list? If no, What’s the next goal?

• • Go the next cycle of PDCA

I’ll use an example in Part II.