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Learn value stream mapping: lessons, exercises, calculators

A free learning center for value stream mapping and future-state design: clear lessons with formulas, interactive calculators, self-tests and exercises you work on directly in the editor. For students, lean coordinators, CI managers and consultants.

How it works: read a lesson, take the self-test, open the template in the editor and do the math yourself. All templates are free and need no sign-up. Open the editor · Printable data collection sheet · Excel data sheet (CSV)

Beginner

BeginnerValue Stream Mapping: Definition, Steps, Metrics and Limits

Value stream mapping explained: definition, five steps, symbols, key metrics and limits. With a free online tool to draw your own VSM.

10 minutes · with exercise in the editor
BeginnerValue Stream Mapping Symbols: Rother/Shook and Erlach Compared

All value stream mapping symbols explained: process, data box, inventory, supermarket, FIFO, kanban, heijunka, kaizen burst. Free online tool.

7 minutes · with exercise in the editor
BeginnerTakt Time Calculation: Formula, Example and Calculator

Takt time = available working time ÷ customer demand. Formula, worked example, common mistakes, free online calculator and the difference from cycle time.

6 minutes · with exercise in the editor · with calculator
BeginnerProduction Lead Time, Inventory Days and the VSM Timeline

How the value stream map timeline works: inventory days, cycle time per process, lead time, value-added ratio and flow factor. Free online calculator.

7 minutes · with exercise in the editor · with calculator
BeginnerValue Stream Mapping in Excel: Import Your Data Instead of Drawing the Map

Why Excel and PowerPoint fall short for value stream maps: import process data from Excel, export maps to PDF, PowerPoint and Excel. Free online tool.

5 minutes · with exercise in the editor
BeginnerValue Stream Mapping Metrics and Abbreviations: C/T, C/O, EPEI, L/T

Value stream mapping glossary: every metric and abbreviation with definition, formula and unit, based on Rother/Shook. Free online VSM tool.

6 minutes · with exercise in the editor
BeginnerFree Value Stream Map Templates: Data Collection Sheet, Excel Data Sheet, Starter Maps

Free templates, no sign-up: printable data collection sheet for the current state, Excel/CSV data sheet for import and eight starter maps in the browser.

4 minutes · with exercise in the editor
BeginnerLean Manufacturing Explained: Principles, Example and How to Start

Lean manufacturing explained simply: flow, takt, pull and perfection in a worked example, lead time cut from 11.3 to 4 days. With video and free template.

9 minutes · with exercise in the editor
BeginnerThe 8 Wastes of Lean (Muda): How to Spot and Eliminate Them

The 8 wastes of lean (muda) with TIMWOODS: Ohno's seven plus unused talent, examples from a worked value stream and a waste walk guide. Free online tool.

9 minutes · with exercise in the editor
BeginnerKaizen and PDCA: Continuous Improvement in Practice

Kaizen explained simply: the PDCA cycle, kaizen vs. kaikaku, kaizen bursts on the value stream map and three rules that make improvement stick. With video.

8 minutes · with exercise in the editor
BeginnerPush vs. Pull in Manufacturing: Kanban, FIFO and Pacemaker Explained

Push vs. pull system compared: weekly schedule vs. kanban loop, FIFO lane and pacemaker in a worked example. Rule of thumb, video and free online tool.

8 minutes · with exercise in the editor

Intermediate

IntermediateValue Stream Map Example: Steering Bracket Step by Step

The classic value stream map example step by step: five processes, 60 s takt time, 11.3 days lead time. Recalculate it in the free online tool.

12 minutes · with exercise in the editor
IntermediateValue Stream Mapping Exercise with Solution: Pump Assembly

VSM exercise with model solution: takt time, bottleneck, inventory days, changeover, supermarket and actions. Work on it in the free online tool.

25 minutes · with exercise in the editor
IntermediateValue Stream Design: Guidelines for the Future State

From current to future state: continuous flow, FIFO, supermarkets with kanban, pacemaker, leveling, EPEI. Design guidelines with examples, free online tool.

10 minutes · with exercise in the editor
IntermediateGemba Data Collection: Checklist for Mapping the Current State

What data to collect for each process and inventory, how to time cycle times with a stopwatch and which mistakes to avoid. Free data collection sheet.

8 minutes · with exercise in the editor
IntermediateSMED: Reduce Changeover Time and Batch Sizes

SMED step by step: separate internal and external setup, cut changeover time. Worked math for changeover per piece, batch size, EPEI and inventory.

9 minutes · with exercise in the editor

Advanced

AdvancedKanban Calculation: How to Size a Supermarket (Formula and Calculator)

The kanban formula explained: number of cards from daily demand, replenishment lead time, container size and safety factor. With a free online calculator.

8 minutes · with exercise in the editor · with calculator
AdvancedOEE, EPEI and Product Mix: Metrics for High-Mix Production

How OEE, EPEI and demand-weighted cycle time fit together in a value stream. Formulas, a three-product example and a free online OEE calculator.

10 minutes · with exercise in the editor · with calculator
AdvancedOffice Value Stream Mapping: Mapping Administrative Processes

Value stream mapping for order processing and administration: business processes with processing time, wait time and information flow. With example.

7 minutes · with exercise in the editor
AdvancedValue Stream Simulation: Make Variability, Buffers and Bottlenecks Visible

Why a static value stream map underestimates lead time and inventory, and how a free online simulation shows variability, downtime and service level.

12 minutes · with exercise in the editor
AdvancedFuture State Map: The 8 Questions Step by Step, With a Worked Example

Build a future state value stream map with the 8 Rother/Shook questions, worked on a steering bracket: takt, flow, supermarket, pitch. 11.3 → 4.0 days.

14 minutes · with exercise in the editor
AdvancedHeijunka and Pitch: Leveling Production

Heijunka explained: volume and mix leveling, the heijunka box and pitch (takt time × pack-out quantity) with worked example, prerequisites and mistakes.

9 minutes · with exercise in the editor
AdvancedYamazumi and Line Balancing: Distributing Work Across Operators

Yamazumi chart explained: stack work content per operator, calculate operator count from planned cycle time and balance a cell. Free online tool.

9 minutes · with exercise in the editor
AdvancedValue Stream Mapping ROI: Building the Business Case

Business case for the future state: value inventory correctly, separate cash release from annual savings, calculate payback. With example and assumptions.

9 minutes · with exercise in the editor
AdvancedMilk Run and Mizusumashi: Supplying the Line on a Fixed Cycle

Internal milk run with tugger train and mizusumashi: route cycle time, driver utilization, line-side inventory and kanban link. With worked example.

7 minutes · with exercise in the editor

Sources

Rother, M.; Shook, J.: Learning to See (Lean Enterprise Institute, 1999) · Erlach, K.: Value Stream Design (Springer, 2013) · Womack, J.; Jones, D.: Lean Thinking (2003) · Nakajima, S.: Introduction to TPM (1988)