Process Map

Introduction to Detailed Step-by-Step Process Mapping in Lean Thinking

A detailed step-by-step process map is a comprehensive visual representation of a workflow that breaks down each individual step in a process, from initiation to completion. In the context of Lean Thinking, this type of mapping is a powerful tool for identifying value-added activities—steps that directly contribute to delivering a product or service to the customer—and wasteful steps that do not add value, often referred to as Muda (waste in Lean terminology).

By mapping out the entire process at a granular level, organizations can analyze each step critically, identifying inefficiencies, redundancies, and non-value-adding activities that slow down operations, increase costs, or negatively impact customer experience. This approach aligns with Lean principles, which emphasize eliminating waste, improving flow, and maximizing value for the customer.

Objectives of a Detailed Step-by-Step Process Map in Lean Thinking

1. Visualizing the Current State – Clearly defining how work is currently performed, including every decision point, handoff, and rework loop.

2. Distinguishing Between Value and Waste – Categorizing each step into one of three categories:

• Value-Added (VA): Activities that directly contribute to fulfilling customer requirements.

• Non-Value-Added but Necessary (NVA-N): Required steps due to regulations, safety, or compliance.

• Non-Value-Added (NVA/Waste): Steps that create delays, excess motion, overprocessing, or rework.

1. Identifying Process Bottlenecks – Highlighting delays, backlogs, or inefficiencies that impact flow.

2. Establishing a Baseline for Improvement – Providing a foundation for streamlining, automation, or process redesign.

Applying Lean Thinking to Process Mapping

A Lean-driven process map is not just about documenting steps—it is about challenging the necessity of each step and continuously striving to remove unnecessary complexity. Teams should ask:

• Does this step add direct value to the customer?

• Is this step necessary due to compliance or regulatory reasons?

• Can this step be simplified, automated, or eliminated?

By focusing on these questions, organizations can redesign workflows to enhance efficiency, reduce costs, and improve customer satisfaction.