Mastering Complexity with Mixed Model Value Stream Mapping (MMVSM)
Production lines are expected to handle multiple product variants. They need to meet tight schedules and fluctuating customer demands.
This is where Mixed Model Value Stream Mapping (MMVSM) comes into play. Traditional value stream mapping works well for straightforward processes, with a single product on a single production line, but most manufacturers manage a variety of products with shared resources.
What is Mixed Model Value Stream Mapping?
Mixed Model Value Stream Mapping (MMVSM) is a method that identifies how to efficiently produce multiple product types through the same production system.
This strategy recognizes that not every product will have the same steps, timing, or materials. It makes sure that processes can handle these differences without causing delays or bottlenecks.
It is designed for situations where a mix of products flows through shared resources - for example, workstations or machinery that can be used for several different products that a business produces. And it's also designed for times when variations in demand lead to constant adjustments, to keep production running smoothly.
When Does MMVSM Make Sense?
Mixed Model Value Stream Mapping is especially useful for industries where product variety is essential, such as automotive manufacturing, pharmaceuticals, and chemicals.
You can easily imagine it: let's consider an automotive factory. A given production line might make several different car models, and each of those models might have different trims, features, and customizations.
In the same way, pharmaceutical companies often run different product formulas through the same processing equipment.
Or a very simple example: you've no doubt seen food labels that say, "Made on equipment that also processes xyz."
In each of those cases, you need to minimize downtime and manage changeovers while maintaining high throughput.
Managing Variability and Complexity
One of the biggest challenges in mixed model production is dealing with variability. Not all products take the same time to complete, nor do they require the same resources. MMVSM captures these differences by focusing on cycle times, setup times, and takt times for each model in the system. It provides a way to see how these variables interact, helping manufacturers identify where bottlenecks are likely to occur.
Because multiple products rely on shared resources, MMVSM also highlights where demand surges or scheduling conflicts could create delays. eVSM software, for example, lets you take into account when it looks like one of your factories is going to go on strike, or other HR issues.
This means production managers can take action ahead of time, and use strategies like load leveling (or Heijunka), to smooth out production schedules and avoid bottlenecks caused by sudden spikes in orders.
Creating a Future State with MMVSM
Mapping out the current state is the first step in MMVSM. This will help you see where the flow breaks down and where waste or inefficiencies are lurking.
Then, manufacturers can design a future state that reduces changeovers, balances workloads across resources, and ensures production meets demand with minimal waste.
This future state might involve changes to scheduling, resource allocation, or even the layout of the production line.
The goal is always the same: to improve efficiency, reduce lead times, and create a system that can adapt to changes in demand without skipping a beat.
Why MMVSM Matters for Modern Manufacturing
Customers expect faster delivery times and more product variety compared to the past, and manufacturing systems must be agile. Mixed model value stream mapping means you can build flexibility into complex production processes. It helps manufacturers understand how variations in products and demand affect their operations and provides a roadmap for minimizing downtime and maximizing throughput.
With the right tools, like eVSM software, companies can take MMVSM even further. eVSM enables detailed mapping of complex production lines, making it easier to visualize mixed model flows and spot potential improvements. In fact, eVSM calculates each of the lead time, capacity, cost, inventory, resource KPI's with supporting capacity charts, lead time chart, resource balance chart, cash river plot, etc.
By making use of these insights, manufacturers can remain competitive, even as they juggle more products and tighter timelines. eVSM even lets them create their supply network maps and link them to their production value stream maps.
For companies facing the challenge of producing multiple products on shared lines, mixed model value stream mapping offers a clear path forward, balancing efficiency with flexibility. When done right, it unlocks the full potential of a production system, turning what could be chaos into a streamlined operation built for modern manufacturing.
And one of the best parts of our day is knowing that clients often ROI while they are still on the free trial of eVSM software. This is because the free trial includes some serious hands-on work with our team. Check out your options here, and get in touch with us to get started.