Prepare a Future State Map
A careful study of the current state map for the garment manufacturing example shows that each worker is responsible for a single step. Hence, any lag or retardation in the progress of one worker can slow down the progress in completing an entire batch.
Most garment manufacturing companies use "kanban" techniques as their means to achieve lean production. This commences from the time it takes for raw materials to be delivered and from the production's commencement at pattern-making stage. It is at this point of production that instructions are clearly marked for the cutters and the assemblers.
However, the markings and measurements have to be precise because they serve as guidelines for the cutter and the stitchers. This is also where computer-aided designs and computer-aided cutting machines are most useful.
"Kanban" is also known as the just-in-time method, which adheres to the practice of supplying raw materials in quantities that are commensurate to the expected time that a batch is completed. Hence, moving the workers as close to each other as possible and up to the extent that floor space allows supports a team-coordinated workflow process.
The next worker in line can check the work passed on to him or her before proceeding; any adjustments or alterations can be made before further work is performed. Cross-training the workers enables each one to discern any errors, as well as allow any one of them to perform any work process.
As an example, cutters and stitchers are trained to understand the markings--e.g., black-marks are for outer layers while blue-marks are for the lining, as well as any other coded instructions to be uniformly observed.
Explore these possibilities and plot them on a new value stream map, to be labeled as the “future state map." Calculate the values-added, the non-value stages and the time-allotments eliminated. Highlight the improvement plans where physical changes, trial-runs and workshop are required. That way, plans for implementations are properly laid out to ensure that deployment procedures will run as smoothly as possible.