As AI tools reshape how we work, the classic 7 Rs framework has never been more relevant. If you ever take a Lean Management/Six Sigma course, one of the exercises that they teach you is to create an “Ideal Process” where all non-value steps have been removed. While many of those were impossible in the past, now with AI, sometimes you really can get there. Here’s some of the ways that we are applying lean principles to AI implementation:

REMOVE: AI-powered analytics now identify waste in real-time, automatically flagging non-value-add activities that were previously invisible in your value stream map.

REDUCE: Machine learning optimizes resource allocation, cutting cycle times and eliminating complexity through predictive scheduling and demand forecasting.

REASSIGN: Tasks naturally migrate to their optimal performers – humans for creative problem-solving, AI for data processing and pattern recognition.

RELOCATE: Digital twins and IoT sensors reveal the perfect positioning of resources, with AI suggesting layout optimizations based on actual flow data.

REORGANIZE: AI identifies bottlenecks instantly and recommends workflow restructuring, turning your value stream map into a living, breathing optimization tool.

RETHINK: Generative AI challenges fundamental assumptions about processes, offering fresh perspectives on “why we do what we do.”

REDESIGN: When incremental improvements aren’t enough, AI simulates entirely new process architectures before implementation.

The game changer? Modern value stream mapping tools powered by AI can now track every step, measure true value-add time, and continuously optimize flows without human intervention.
What non-value-add activities has AI helped you eliminate in your organization?
The Pinney Group, Ignitia-AI
#ProcessImprovement #ValueStream #DigitalTransformation