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Value Stream Mapping 2.0: From Paper Maps to AI-Driven Flow Intelligence
From Paper Maps to AI-Driven Flow Intelligence
Avoid the governance and workforce-trust mistakes that sink most digital VSM pilots Written for plant managers, industrial engineers, and Lean practitioners in manufacturing — including leather, footwear, and other high-mix discrete production — this is a practical field guide, not a hype-driven AI manifesto. Every technique is scoped to what a mid-sized manufacturer can actually build, validate, and trust. Includes a 90-day quick-start worksheet, a sample data dictionary template, and a vendor-neutral technology checklist. The map still serves the people on the floo
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About
About the Book
Value Stream Mapping made Lean visible. But the classic VSM walk — clipboard, stopwatch, one snapshot a year — was built for a factory that changes slowly. Today's plants don't. Value Stream Mapping 2.0 shows you how to rebuild VSM's data backbone for 2026: connecting the MES, ERP, and sensor data your plant already generates into a living digital twin that updates continuously instead of decaying the moment the walk ends. Inside, you'll learn how to:
- Build a digital twin of your value stream without a data science team or enterprise budget
- Use process mining to reconstruct how orders actually flow — not how the documentation says they should
- Apply computer vision and low-cost IoT sensors to close data gaps at manual stations
- Detect waste automatically with machine learning, before it becomes a visible problem
- Run scenario simulations before committing floor time or capital to a change - Identify a moving bottleneck in real time across shifting product mix
- Avoid the governance and workforce-trust mistakes that sink most digital VSM pilots Written for plant managers, industrial engineers, and Lean practitioners in manufacturing — including leather, footwear, and other high-mix discrete production — this is a practical field guide, not a hype-driven AI manifesto. Every technique is scoped to what a mid-sized manufacturer can actually build, validate, and trust.
Includes a 90-day quick-start worksheet, a sample data dictionary template, and a vendor-neutral technology checklist. The map still serves the people on the floor. It just stays current now.
Author
About the Author
Emil Popa
Popa Emil is a manufacturing and engineering professional with over 15 years of experience leading operational excellence, process optimization, and industrial transformation initiatives. With expertise in Lean Manufacturing, Six Sigma, and engineering management, he has worked extensively on improving performance, developing teams, and driving continuous improvement cultures.
As both an industry leader and technology educator, he is deeply committed to mentoring young engineers and preparing future professionals for the realities of modern manufacturing. His work combines technical expertise, leadership principles, and practical experience to deliver actionable knowledge for engineers, managers, and innovators worldwide.
“Operational excellence starts with people who never stop improving.”
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