Page 64 - The Toyota Way Fieldbook

42 THE TOYOTA WAY FIELDBOOK

fixing individual processes. The point of improving individual processes is to
support the flow.
The maps also provide a “common language” and understanding so that
everyone has the same vision. Like a road map, the value stream mapping tool
shows the road for the journey, but it is only a guide. It does not detail what you
will find along the way. You must have a thorough understanding of the basic
concepts and how to create processes that adhere to them. This is when it is very
helpful to have someone who has previously made the journey. They not only
know where they’re going, but they can save countless hours otherwise wasted
by taking wrong turns!

Developing a Current State Map

Developing a current state map seems a simple enough task. Just go out and
document what you see. Show the processes and the flow of material from one
process to another. That sounds easy enough! What we see in reality is people
getting “stuck” in a mapping quagmire. Many people try to make the map “right”
when in fact the purpose of mapping is to see that things are far from right. As
we will see in Chapter 6, lack of standardization in the work area will at times
make the process of capturing reality very difficult. Don’t despair! The purpose
of the current state map is to understand the nature of the processes so that an
effective future state can be created.

TIP
Make the Level of Detail Fit the State of the Process
During the initial cycle through the continuous improvement
spiral, data collected from the process may not be completely
“clean.” This is often the case prior to achieving a baseline of
standardization (on the first pass). Many hours can be wasted in
futile attempts to gather data at a detailed level.
For the initial current state mapping activity, keep data at a
high level or “overall” for the process. Use rough estimates of
key parameters. Process-specific detailed data can be gathered
later, when activity is initiated in a particular area.
The main purpose of the first mapping of the current state is
to understand the condition of material flow in the value stream
and the inhibitors to the flow, as well as understanding the infor-
mation flow process and the level of activity necessary to sustain
it. The future state then provides a high level picture of the flow
of material and information, which can be later refined when the
process is stabilized.