How to Apply Value Stream Mapping (VSM) to Flexo Environments

Introduction: What Is Value Stream Mapping?

Value Stream Mapping (VSM) is a core lean management tool used to visualize and analyze the flow of materials and information throughout a production process. Its goal is to identify value-added and non-value-added steps so organizations can streamline operations, reduce waste, and increase efficiency.

In flexographic printing, VSM can be particularly impactful because the process involves multiple departments (prepress, mounting, press, finishing) and complex handoffs. Applying VSM reveals bottlenecks, inconsistencies, and delays that often go unnoticed.

Why VSM Works in Flexo Printing

Flexo workflows are diverse and can vary significantly between jobs. VSM helps bring structure and clarity by:

• Mapping all steps from job order to shipment
• Identifying delays and inefficiencies between prepress, plate mounting, and printing
• Highlighting redundant approvals, excessive handling, or long setup times
• Uncovering disconnects between departments or unclear communication flows

Once these pain points are visualized, targeted improvements can be made.

Getting Started: Define the Scope and Team

Before drawing a value stream map, it’s important to define the boundaries:

• Will you map from customer order to finished product, or just prepress to press?
• What is the job type: short-run labels, long-run packaging, or multi-color work?

Assemble a cross-functional team including prepress, mounting, press, planning, and quality. Each stakeholder brings key insights into where delays or rework typically occur.

Step-by-Step: Creating a VSM for Flexo

Here’s how to build a basic value stream map in a flexo environment:

1. Identify the product or job family to focus on (e.g., labels, cartons).
2. Map the current state, starting with the customer order and ending at shipment.
3. For each step, note:
   • Process time (PT)
   • Wait time or queue (WT)
   • Inventory or WIP levels
   • Handoffs between departments
4. Visualize information flows like job tickets, proofs, and approvals.
5. Identify “waste zones”—steps with high wait time, high rework, or unnecessary motion.
6. Define the future state by eliminating non-value-added steps or reducing handoffs.

Common Findings in Flexo VSM Projects

When flexo converters conduct VSM exercises, they often uncover:

• Long delays between job approval and plate readiness
• Bottlenecks in manual plate mounting or sleeve retrieval
• High variability in setup times due to inconsistent sleeve quality
• Excessive rework loops in file preparation or press registration
• Manual data collection or missing job tracking

These findings serve as a blueprint for digitalization and lean transformation.

Turning Insights into Action

Once the current state is mapped, the next step is prioritizing improvements:

• Automate time-consuming steps like plate mounting or sleeve inspection
• Introduce scheduling buffers to reduce press downtime
• Digitize job tracking with AVManager or ERP integrations
• Train staff on visual management and standard work
• Invest in traceability tools and automated storage systems

Lean is not about working harder—it’s about eliminating effort that doesn’t add value.

Conclusion: A Roadmap to Leaner Flexo Operations

Value Stream Mapping empowers flexo printers to rethink how work flows through their organization. It provides a powerful lens to see hidden inefficiencies and coordinate improvements across departments. With a clear map and cross-functional alignment, VSM lays the groundwork for leaner, faster, and more reliable flexographic production.

At AV Flexologic, we provide automation solutions that align perfectly with lean principles. For example, our SAMM 3.0 automatic plate mounter eliminates variation and waste during the mounting process by using advanced robotics and image recognition. It ensures accurate, repeatable mounting in seconds, reduces the need for skilled manual labor, and frees up operators to focus on value-added tasks. By integrating systems like SAMM 3.0 into the value stream, converters can directly address common bottlenecks.

By focusing on the value stream, not just individual processes, converters can unlock significant gains in uptime, quality, and responsiveness—turning operational clarity into competitive advantage.