Novel Lean framework for Kaizen prioritization: combining mapping techniques to enhance efficiency and budget allocation

Nowadays, companies operate in increasingly competitive markets, requiring them to constantly optimize processes by eliminating inefficiencies to maintain a competitive advantage. In this context, Lean philosophy provides a strategic approach to identify and remove inefficiencies through continuous improvement activities (Kaizen). The purpose of this study is to address a key limitation of Lean philosophy, that lacks of a structured approach for prioritizing Kaizen initiatives, by integrating managerial control and cost-effectiveness perspectives into Lean decision-making. Methodologically, the research enhances the hybrid mapping technique developed by (Soliman, M., Oliveira Esteves, O., Trevisan, M., & Fogliarini Segatto, G. (2022). A tentative integration of value stream mapping (VSM) and BPMN for improved process mapping. Knowledge and Process Management, 29(4), 371–382. https://doi.org/10.1002/kpm.1729), proposing a novel framework that systematically identifies inefficiencies and ranks improvements according to their value, considering performance impact and potential cost reduction. Tested in a spare parts distribution company, the framework achieved a 40% reduction in critical activities and a 25% overall process optimization. Although limited to a single case study, the research provides a foundation for future validation across different industrial context. From a practical standpoint, the framework supports managers in prioritizing Lean activities under financial and time constraints, enhancing alignment between operational improvements and management control systems. This study adds value by integrating Lean thinking and cost management, providing a flexible framework for strategic and sustainable Kaizen implementation.