Value Stream Map Template
Map steps and inventory to get lead time, processing time and VA ratio.
Example loaded: steel brackets, 4 steps, 460 a day.
- Takt time
- -
- Lead time
- -
- Processing time
- -
- Value-added ratio
- -
Filled boxes are tinted. Click a box to go to it.
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How to fill in the value stream map
- Pick one product family. Products that go through the same steps. Map from the receiving dock to shipping for that family only.
- Enter demand and available time. Customer demand per day and working seconds per day after breaks. The template works out takt.
- Walk the flow and fill each process box. Start at shipping and walk upstream. For each step, record cycle time, changeover, uptime and operators from what you see, not from the routing.
- Count the inventory between steps. Count the parts waiting before each step and in finished goods. The template turns the counts into days using demand.
- Read the timeline. Lead time in days on top, processing time in seconds below. A value-added ratio far below 1% is normal for a first map.
- Mark the improvements. Steps above takt, big inventory piles and long changeovers are where the future state starts. See how to draw a value stream map for the full method.
Value stream map example: steel brackets
A current state map for a bracket family shipped to one customer. Demand is 460 brackets a day. The plant runs two shifts of 7.5 working hours, so available time is 2 × 7.5 × 3,600 = 54,000 seconds a day.
| Step | Inventory before | Days | C/T (s) | C/O (min) | Uptime | Operators |
|---|---|---|---|---|---|---|
| Stamping | 2,300 (coil) | 5.0 | 1 | 60 | 85% | 1 |
| Weld | 4,600 | 10.0 | 39 | 10 | 100% | 1 |
| Assembly | 1,100 | 2.4 | 62 | 0 | 100% | 1 |
| Pack | 1,600 | 3.5 | 40 | 0 | 100% | 1 |
| Finished goods | 2,700 | 5.9 |
The math
Inventory days = units ÷ 460: 2,300 → 5.0, 4,600 → 10.0, 1,100 → 2.4, 1,600 → 3.5, 2,700 → 5.9
Lead time = 5.0 + 10.0 + 2.4 + 3.5 + 5.9 = 26.7 days
Processing time = 1 + 39 + 62 + 40 = 142 s
Value-added ratio = 142 ÷ (26.7 × 54,000) = 0.0098%
Every cycle time is under the 117-second takt, so capacity is not the problem: the brackets spend 26.7 days waiting for 142 seconds of work. The 10 days in front of weld come from the 60-minute stamping changeover, which makes stamping run big batches. That is where the future state starts. Press Load the filled example above to see this map drawn, then change the numbers. For current and future state maps with what-if scenarios, see VSM Pro, the value stream mapping software.
Why this tool matters
A value stream map shows where the time goes. In most factories a part spends days or weeks waiting and only minutes being worked on. The map makes that visible in one picture, so the team improves the flow instead of making one machine faster while parts still wait in front of it.
Facilitator tip
Walk the flow from shipping back to receiving and count the inventory yourself. Walking upstream keeps you thinking about what the customer pulls, and your own counts are always more honest than the system.
Frequently asked questions
How do you calculate lead time on a value stream map?
Divide each inventory count by the daily customer demand to get days of inventory, then add them up, including raw material and finished goods. 1,100 parts waiting with a demand of 460 a day is 1,100 ÷ 460 = 2.4 days. The total is the production lead time.
How do you calculate the value-added ratio?
Add the cycle times of the process steps to get the processing time, then divide by the lead time in the same unit. This template converts lead time days to seconds with your available working time per day: 142 s ÷ (26.7 days × 54,000 s) = 0.0098%.
What goes in a VSM data box?
At least cycle time (C/T), changeover time (C/O), uptime, number of operators and available time. Add batch size, scrap rate or shifts when they matter for the flow you are mapping.
What is the difference between a current state and a future state map?
The current state map shows how the product flows today, measured on the floor. The future state map shows how it should flow after improvements such as pull, smaller batches or a pacemaker process, with the lead time it should reach.
Can I make a value stream map in Excel?
Yes, many people draw one with Excel shapes, but the math is manual. This template does the lead time, processing time and takt math for you and exports CSV that opens in Excel. For current and future state maps with what-if, use VSM Pro.
What is takt time on a VSM?
Available working time per day divided by customer demand per day. 54,000 s ÷ 460 parts = 117 s. Any process with a cycle time above takt cannot keep up with demand without overtime or extra capacity.