Questions (see image):

a) Eliminating the queue of work dramatically quickens the time it takes a part to flow through the system. What are the disadvantages of removing those queues?

b) How do you think the machine operators would react to the change?

c) What would you do to ensure that the operators were kept busy?

Value stream mapping involves first developing a baseline map of the current situation of a company's extemal and/or internal operations, and then applying lean concepts, developing a future state map that shows improved operations. Exhibit A, for example, shows the current state with a production lead time of 4.5 days. This system is a batch/push system, resulting in long delays and inventory buildups. Exhibit B shows the future state map with a production lead time of 0.25 day. This was accomplished by moving to a continuous flow pull system and attacking the seven wastes. Exhibit A. Current State Exhibit B. Future State