Why value streams need a fresh look
Manufacturers have weathered an intense period of disruption. From pandemics to geopolitical shocks, value streams have shown how quickly performance can deteriorate when unexpected events interrupt material or information flow. Traditional value stream analysis offers transparency and waste reduction, yet it overlooks a critical factor: resilience. To withstand future crises, companies must first understand where vulnerabilities exist.

A systematic way to uncover hidden risks
New research introduces a structured approach for identifying risks within a value stream. Instead of relying solely on expert judgement, the method breaks a value stream into its core elements using the familiar symbols of value stream mapping. Each element, whether a production process, logistics process, storage point or business process, is then examined using a diagnostic model that highlights potential deviations in inputs, outputs or resources.

This model brings consistency. Risks are identified at the same level of detail across the value stream, reducing blind spots and enabling a complete picture of where disruptions may emerge. The approach focuses on realistic threats within the system rather than attempting to predict every external shock.

Proven in a learning factory environment
The diagnostic models were tested in TU Darmstadt’s process learning factory, where they were applied to milling and assembly processes. The result was a clear, comprehensive overview of the risks that had influenced performance in the past five years. The method proved efficient, practical and easy to use in a real production setting.

Enabling resilience by design
By embedding systematic risk identification into value stream work, manufacturers gain a stronger foundation for resilience assessment. This supports better planning, smarter reconfiguration decisions and ultimately a more robust value stream that can adapt when conditions change.

This article is based on the peer-reviewed publication Identification of risks in value streams for resilience assessment – diagnostic models (Procedia CIRP, 2024)