This post is about how I run a value stream mapping workshop as part of an Agile/Lean readiness assessment or as part of ongoing process improvements.

Value Stream Map’s are very useful for understanding how your current process works. My initial understanding came via Mary Poppendieck (books and training). Later I learned the details from the book Learning to See: Value Stream Mapping to Add Value and Eliminate MUDA by Mike Rother and John Shook; it’s all about manufacturing but the principles hold.

Workshop is ~10 people x 3 hours

For this meeting, I ask for a cross-functional group that can define the steps involved with going from concept to cash. This group may be in the 5 to 15 person range depending on the organization. Depending on how many people you have you may want to split them into multiple groups. Groups can do the same or different processes. My rule is to get to as small a group as you can and still have enough knowledge of the process.

With regard to time – 2 hours may be enough for a small company while a large bank may require the full 3 hours.

Slides used to Introduce Value Stream Mapping

Below are the slides I use to introduce the workshop. Mostly you’ll just see pictures that I use to introduce the concepts, so you gotta know this stuff well. In addition to value stream mapping, I talk about Muri, Mura, Muda and have them think about the 7 types of waste.

View more presentations from Michael Sahota.

Explain how to create a Map

Before starting the exercise, I run through creating a value stream map with them so they get a feel for how it works and agree on conventions.

As people indicate what the steps in the value stream map are, I write up each step and create the legend shown on the left. It doesn’t really matter what process you use – the point of this part is to give them a feel for identifying each of the parts. Go through a few steps until you can see they are getting the hang of it. Remember to write the time on value added and waste stickies (missing in legend).

Size matters. Queue size, that is. It is important to show how much WIP (work-in-process) there is at each step. People often know things like: we have a product roadmap with 200 features in it or 9 features waiting for development.

Some teams may not feel comfortable identifying any activities as waste. That’s OK. They may not be ready for that yet.

Mapping Exercise

It helps to pick a concrete project that is typical for the organization. Something like an average feature, typical client request or urgent defect fix. This helps people move away from a conceptual process to talk about what actually happens in real life.

It is a good idea to warn people that they may be surprised with how things actually work. Taiichi Ohno, one of the founders of Toyota Production System, joked that it is good to have a poor starting place so there are easy opportunities to show process improvement.

During the exercise, I float between the groups to answer questions and make sure things are on track. After about 20 minutes the teams are usually cooking and can proceed on their own.

Once everyone is finished, each team presents it’s value stream map to the large group. Sometimes there are minor corrections, but these are usually fine details that don’t change the big picture.

Example Value Stream Map

Below is an example (click for a large image) of a completed value stream map for funded development at a 50 person product company. In this particular case, the company noticed that 5 days of planned work actually took 15 days (with rework) plus another 10 days of waste due to communication overhead.

Special enhancements:

• Along the top we have communication waste – this is the extra time needed to manage a project in a dysfunctional process that spans 9 months.
• Below the main flow we have rework arrows. Each arrow indicates the % chance that the work item needs to return to an earlier step. As can be seen, there are multiple return trips after reaching production.

Debrief with management

At the start, I explain the overall activity and its purpose. Together with some of the original authors of the map, we walk through the steps. I stick to explaining the Value Stream Map concepts and let others explain the content. Managers are usually surprised at how long it takes to complete work.

It is especially important to clarify that we are talking about the Lean concept of system efficiency - defined as time working on product/elapsed time. This will be unrelated to other measures of efficiency at the company.

The usual follow-up on this workshop is one to specify the desired future state. Of course, all of this is a great candidate for using the A3 technique.

This post shows the A3 technique and how it is an effective management tool.

The contents of this post are my summary of THE BOOK on this subject: Managing to Learn: Using the A3 Management Process to solve problems, gain agreement, mentor and lead – by John Shook. Available via Lean Enterprise Institute and Ocapt (in Canada).

Why A3?

Over the last year, I have used A3 to solve serious problems myself as well as with clients that I am coaching. I am blown away by how effective it is. I think of it as the howitzer (big gun) of problem solving and use it for complex problems.

Root cause analysis tools are very helpful, however, do not provided a context for resolving problems. A3 is a complete process. If you are not familiar with root cause analysis, see my related blog post.

What is an A3 anyway?

As shown in the middle of the diagram below, A3 is the name for a large sheet of paper (17″ x 11″). With the A3 technique, it is filled up with useful information. Space is intentionally limited to make sure only the most relevant information is shared. At Toyota, the A3 report is used to drive company decisions from shop floor to senior management.

Let’s walk through the sections:

1. Problem – What is the problem that is causing problems? Also, give attention to the title as the summary.
2. Background – How did you decide to work on this problem? What is business problem?
3. Current Conditions – Describe the current conditions with visuals and numerical data that you have analyzed.
4. Goals/Targets – What is the desired target state? This is the place to use SMART goals.
5. Root Cause Analysis – What are the underlying causes? Use ask why five times and fishbone diagram.
6. Countermeasures – How will you reach goal state? What activities can be identified that will address root causes and how were the best ones selected?
7. Plan – What is the plan for getting there? When will the countermeasures be implemented?
8. Followup – What were the results of deploying the countermeasures? Now that there is new information, it is time to revisit the A3.

You may have noticed that this is an elaborated version of PDCA – Plan Do Check Act. This is the heartbeat of a learning organization.

It takes time and effort to complete an A3. Weeks not days. Use when appropriate.

Tips: Experts strongly recommend using real paper. Yes, you will need to re-write; editing is a good thing. A wiki is great for details, but not for thinking and summarizing.

A3 to gain agreement, mentor and lead

In this section, I want to share how the A3 technique is a powerful management tool.  Consider the following diagram:

A3 is about people working together to solve problems. The Japanese word Nemawashi is about going to the roots to reach consensus and alignment in a deep way. An A3 changes the way we work and communicate with each other. When meetings start by reviewing the parts of the A3 that have been completed, there is great focus on the remaining work. I have also seen new project participants brought up to speed very rapidly.

At Toyota, the A3 is used to do work. It is used to solve problems, make (set-based) decisions and execute plans.

Lean is famous for using pull to deliver the right part at the right time at the right place. With A3, the person driving the change effort can pull authority by working with other people and demonstrating leadership. It is chilling to see this work. I was coaching a junior analyst to put together an A3 on a production problem. When the issue escalated, the VP recognized the analyst as the expert and asked him to tell people what to do to fix the problem even though he had no formal or informal leadership role.

Finally, the A3 can be used to build a learning organization. One key aspect is to celebrate mistakes. This is also common with building an innovation culture through Improv or theatre techniques. At Toyota, it is used to develop people by helping them think for themselves to solve problems. A manager’s job is to build people and mentoring people on the A3 is a great way to do it. (Like a self-organizing team, but on an individual scale.)

I wish I had a real A3 to share, but the better ones I have are client confidential.

If you want to learn more, I urge you to buy the book or check out webinar on Managing to Learn.