Value Stream Mapping
(VSM) & Yamazumi Training
A hands-on training program designed to analyse processes end to end, make waste visible and improve flow. Participants map the current state, identify bottlenecks and design the future state.
Why VSM and Yamazumi?
VSM makes an entire process visible on a single page — the value-adding steps, the waiting, the inventory points and the waste. Yamazumi balances workload operator by operator and optimises capacity against takt time.
Program Content
The training covers every step, from VSM fundamentals to current state analysis, from takt time calculation to future state design and workload balancing with Yamazumi.
01 VSM Fundamentals
- What is value stream mapping and why is it used?
- The place of VSM within lean manufacturing
- VSM symbols and the mapping language
- Separating value-adding from non-value-adding steps
- Reading and interpreting the current state map
02 Current State Analysis
- The steps of drawing a current state VSM
- Identifying flow, waiting and inventory points
- Measuring process time and cycle time
- Pinpointing bottlenecks and waste
- Creating loss visibility by line
03 Takt Time & Future State
- Calculating and interpreting takt time
- Comparing process times against takt time
- Designing the future state map
- Designing a pull system and continuous flow
- Setting improvement priorities
04 Workload Balancing with Yamazumi
- What is a Yamazumi chart and how is it built?
- Workload distribution analysis by operator
- Capacity optimisation against takt time
- Removing workload imbalances
- Integrating Yamazumi and VSM
Daily Program Flow
The morning block covers VSM theory and mapping techniques; in the afternoon a current state map is drawn for a chosen process, bottlenecks are identified and improvement proposals are developed for the future state.
Application & Workshop (13:30 – 16:00)
- Drawing a current state VSM for the chosen process
- Determining times, waiting and bottlenecks
- Workload distribution through Yamazumi analysis
- Developing improvement proposals for the future state
VSM Fundamentals & Mapping Language
Covers the VSM philosophy, symbols, separating value-adding from non-value-adding steps, and reading the current state.
Takt Time, Future State & Yamazumi
Covers takt time calculation, future state design and workload balancing methods with Yamazumi.
Current State VSM Workshop
A group-based current state map is drawn for the chosen process; waiting and bottlenecks are identified.
Future State & Improvement Plan
The Yamazumi analysis is completed, the future state map is designed and an improvement action plan is produced.
By the End of the Training, Participants…
Participants who complete the training can apply VSM and Yamazumi independently, make waste and bottlenecks visible in their own processes and build an improvement action plan.
Being able to analyse processes end to end
Being able to identify waste and bottlenecks
Understanding takt time and the logic of flow
Being able to raise efficiency by balancing workload
Who Is This Training For?
VSM & Yamazumi training suits every operations team that wants to map processes end to end, make flow losses visible and optimise workload balance.
Manufacturing Engineers
Teams that want to make line and process flow analysis visible with VSM.
Planning Teams
Teams that want to optimise production flow and capacity balance against takt time.
Continuous Improvement Teams
CI professionals who systematically identify improvement opportunities with VSM and Yamazumi.
Operations Managers
Managers who want to analyse process performance holistically and take strategic decisions.
Consultant & Instructor
With 24 years of automotive experience, Ertuğrul Turgay integrates value stream mapping and workload balancing with WCM and Lean Manufacturing methodologies to design programs that create measurable improvement on the shop floor. He treats VSM and Yamazumi not as theoretical tools but as the starting point of real shop-floor transformation.
Request a Quote for VSM & Yamazumi Training
Contact the Opexera team for process selection, mapping workshop design and content adaptation tailored to your organisation.