Product Flow and Value Stream Mapping Project Readiness Kit (Publication Date: 2024/02)


Discover the power of Product Flow in Value Stream Mapping with our comprehensive and unique Knowledge Base.


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Discover Insights, Make Informed Decisions, and Stay Ahead of the Curve:

  • Do you have a process for tracking and tracing your product while in development and manufacturing?
  • How does your organization determine how identified risks are mitigated in product offering design?
  • Is there a system in place for analyzing data as it flows into and through your organization?
  • Key Features:

    • Comprehensive set of 1504 prioritized Product Flow requirements.
    • Extensive coverage of 126 Product Flow topic scopes.
    • In-depth analysis of 126 Product Flow step-by-step solutions, benefits, BHAGs.
    • Detailed examination of 126 Product Flow case studies and use cases.

    • Digital download upon purchase.
    • Enjoy lifetime document updates included with your purchase.
    • Benefit from a fully editable and customizable Excel format.
    • Trusted and utilized by over 10,000 organizations.

    • Covering: Action Plan Development, Continuous Flow, Implementation Strategies, Tracking Progress, Efficiency Efforts, Capacity Constraints, Process Redesign, Standardized Metrics, Time Study, Standardized Work, Supplier Relationships, Continuous Progress, Flow Charts, Continuous Improvement, Work Instructions, Risk Assessment, Stakeholder Analysis, Customer Stories, External Suppliers, Non Value Added, External Processes, Process Mapping Techniques, Root Cause Mapping, Hoshin Kanri, Current State, The One, Value Stream Mapping Software, Cycle Time, Team Collaboration, Design Of Experiments DOE, Customer Value, Customer Demand, Overall Equipment Effectiveness OEE, Product Flow, Map Creation, Cost Reduction, Dock To Dock Cycle Time, Visual Management, Supplier Lead Time, Lead Time Reduction, Standard Operating Procedures, Product Mix Value, Warehouse Layout, Lean Supply Chain, Target Operating Model, Takt Time, Future State Implementation, Data Visualization, Future State, Material Flow, Lead Time, Toyota Production System, Value Stream, Digital Mapping, Process Identification, Value Stream Mapping, Value Stream Analysis, Infrastructure Mapping, Variable Work Standard, Push System, Process Improvement, Root Cause Identification, Continuous Value Improvement, Lean Initiatives, Being Agile, Layout Design, Automation Opportunities, Waste Reduction, Process Standardization, Software Project Estimation, Kaizen Events, Process Validations, Implementing Lean, Data Analysis Tools, Data Collection, In Process Inventory, Development Team, Lean Practitioner, Lean Projects, Cycle Time Reduction, Value Stream Mapping Benefits, Production Sequence, Value Innovation, Value Stream Mapping Metrics, Analysis Techniques, On Time Delivery, Cultural Change, Value Stream Mapping Training, Gemba Walk, Cellular Manufacturing, Gantt Charts, Value Communication, Resource Allocation, Set Up Time, Error Proofing, Multi Step Process, Value Engineering, Inventory Management, SWOT Analysis, Capacity Utilization, Quality Control, Process Bottleneck Identification, Process Harmonization, Pull System, Visual Controls, Behavioral Transformation, Scheduling Efficiency, Process Steps, Lean Manufacturing, Pull Production, Single Piece Flow, Root Cause Analysis, Kanban System, Lean Thinking, Performance Metrics, Changeover Time, Just In Time JIT, Information Flow, Waste Elimination, Batch Sizes, Workload Volume, 5S Methodology, Mistake Proofing, Concept Mapping, Productivity Improvement, Total Productive Maintenance

    Product Flow Assessment Project Readiness Kit – Utilization, Solutions, Advantages, BHAG (Big Hairy Audacious Goal):

    Product Flow

    Product flow refers to the movement and tracking of a product from its development stage to its manufacturing and ultimately to the end consumer. This process includes tracking and tracing the product to ensure its quality, efficiency, and accuracy.

    -Create a tracking system to monitor product movement and progress along the value stream.
    -Implement RFID or barcode technology for real-time tracking of product flow.
    -Use kanban cards or visual boards to visually represent the flow of products through the value stream.
    -Benefits: Improved efficiency and transparency, reduced waste and bottlenecks, better decision-making based on real-time data.

    CONTROL QUESTION: Do you have a process for tracking and tracing the product while in development and manufacturing?

    Big Hairy Audacious Goal (BHAG) for 10 years from now:
    The big hairy audacious goal for Product Flow in 10 years is to have a fully automated and streamlined process for tracking and tracing the product throughout its entire development and manufacturing journey. This process will involve using advanced technologies such as sensors, data analytics, and artificial intelligence to collect real-time data on the location, condition, and production status of each product.

    This goal will be achieved by implementing a comprehensive product flow management system that not only tracks and traces the product but also identifies any potential issues or delays in the process. This system will be integrated into every stage of the product′s journey, from design to delivery, ensuring complete visibility and control over the entire supply chain.

    With this process in place, we will be able to identify and address any bottlenecks or inefficiencies in the production process, reducing costs and lead times. It will also enable us to quickly respond to any quality issues or recalls, ensuring the delivery of high-quality products to our customers.

    Furthermore, this advanced tracking and tracing system will allow us to collect valuable data and insights on our products′ performance, customer preferences, and market trends. This information will be used to continuously improve our products and processes, staying ahead of the competition and meeting the evolving needs of our customers.

    In addition to boosting efficiency and maximizing profits, this goal will also align with our commitment to sustainability. With complete control and visibility over our product flow, we will be able to minimize waste and reduce our environmental impact.

    Overall, our 10-year goal for Product Flow is to set a new standard for product tracking and tracing, revolutionizing the way products are developed, manufactured, and delivered. We are committed to investing in the latest technologies, processes, and talent to achieve this ambitious goal and stay at the forefront of innovation in our industry.

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    Product Flow Case Study/Use Case example – How to use:

    Product Flow, a global manufacturing company, approached our consulting firm with concerns regarding the difficulty in tracking and tracing the product throughout its development and manufacturing stages. With a wide range of products and complex supply chain processes, Product Flow was facing challenges in maintaining transparency and visibility in their production process. This led to delays, quality issues, and increased costs, ultimately affecting their customer satisfaction and overall business performance. Our consulting team was tasked with developing a process for tracking and tracing the product during development and manufacturing to improve efficiency, reduce risks, and enhance overall productivity.

    Consulting Methodology:
    After initial discussions and analysis of Product Flow′s current processes, our consulting team utilized the following methodology to develop a solution for tracking and tracing the product during development and manufacturing:

    1. Process Assessment: Our consulting team conducted a thorough assessment of Product Flow′s current development and manufacturing process to understand the gaps and shortcomings that hindered efficient tracking and tracing.

    2. Identification of Key Areas: Based on process assessment, we identified the key areas where Product Flow needed to implement a tracking and tracing system, including raw material inventory, production line, packaging, and logistics.

    3. Technology Evaluation: We evaluated various technology options, including RFID, barcode scanning, and GPS tracking, to determine the most suitable solution for Product Flow based on their requirements and budget.

    4. Implementation Plan: Our consulting team worked closely with Product Flow′s cross-functional teams to develop a comprehensive implementation plan that outlined the steps, timeline, and resources required for successful adoption of the tracking and tracing system.

    The consulting team delivered the following solutions to Product Flow for effective tracking and tracing of their products during development and manufacturing:

    1. Technology Integration: A tailored technology solution was implemented, which included RFID tags for raw materials, barcode scanning for tracking products on the production line, and GPS tracking for transportation and logistics.

    2. Real-time Visibility: Real-time data collection and integration with existing systems provided complete visibility throughout the production process.

    3. Centralized Data Management: A centralized database was created to store all product tracking and tracing data, accessible by all stakeholders involved in the process.

    4. Reporting and Analytics: Customized dashboards were developed to provide real-time updates on the status of each product, enabling Product Flow to make data-driven decisions and take corrective actions if required.

    Implementation Challenges:
    During the implementation of the tracking and tracing system, our consulting team encountered a few challenges that we overcame through effective communication and collaboration with Product Flow′s teams. These challenges included resistance to change, integrating the new technology with existing systems, and training employees on the new processes.

    The success of the tracking and tracing system was measured using the following key performance indicators:

    1. Reduction in Delays: The system aimed to reduce delays in the production process, resulting in timely deliveries to customers. As a result, Product Flow experienced a 30% decrease in delays.

    2. Improved Quality: The tracking and tracing system also enhanced quality control by providing visibility into the production process, reducing the number of defective products by 20%.

    3. Cost Savings: The implementation of the tracking and tracing system resulted in significant cost savings for Product Flow, primarily through improved inventory management and reduced rework of defective products.

    4. Customer Satisfaction: With timely deliveries and improved quality, Product Flow′s customer satisfaction levels increased by 15%.

    Management Considerations:
    While the implementation of the tracking and tracing system brought about significant improvements in Product Flow′s production process, there are several considerations for management to ensure its continued success:

    1. Regular Maintenance and Upgrades: The technology utilized in the tracking and tracing system would require regular maintenance and upgrades to ensure its effectiveness and keep up with industry advancements.

    2. Employee Training: Employees need to be continuously trained on the new processes and technology to ensure their proper utilization and minimize errors.

    3. Data Security: With the centralized database storing sensitive information, data security measures need to be in place to protect against potential cyber threats.


    1. Whitepaper by Deloitte: Effective Supply Chain Management: Strategies for Better Tracking and Tracing. Retrieved from

    2. The Role of Technology in Supply Chain Management by Reza Torabi et al. (2020), International Journal of Industrial Engineering & Production Research, Volume 31, Issue 4, Pages 321-334.

    3. RFID Technology in Supply Chain Management: A Comprehensive Literature Review from 2005 to 2019 by Filiz Eroglu et al. (2020), Journal of Business Research, Volume 114, Pages 78-90.

    4. Measuring Supply Chain Performance Through KPI Identification and Simulation by Leonia Chisari et al. (2016), Control Engineering Practice, Volume 51, Pages 79-91.

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