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Lean management is a suitable methodology for companies that want to improve their productive performance and competitiveness. This study aims to research levels of implementation and internalisation of Lean production tools in Spanish manufacturing companies, and explores differences in behaviour between SMEs and large companies based on data gathered over three time periods. The correlation between Lean adoption and company performance is also analysed.

Company survey data for the years 2012, 2015 and 2018 collected from 354 respondents were used to conduct a longitudinal study on the level of lean tool adoption and internalisation in manufacturing companies.

Over the years, the use of Lean tools has increased, whereas levels of internalisation have remained stable. Lean tool use in SMEs and large companies show significant differences in 2012 and 2015, but this is no longer the case 2018. Results also show that higher Lean tool use helps increase return on sales (ROS), and higher levels of internalisation of tools helps reduce the number of products rejected.

To date, there are no known studies on the use and internalisation of Lean tools or their correlations with business performance indicators in Spanish manufacturing companies.

The value stream mapping (VSM) is a tool created by the lean production movement for redesigning the productive systems. Since, it was theoretically developed, some cases have been published where the mentioned tool has been used; however, there is a need to see how it is put into practice, that is to analyze the level in which theory is able to adapt to real practice, the strengths, weaknesses and the key aspects to be taken into account by the applicant teams to obtain the highest performance of the VSM. This paper aims to discuss all of these aspects.

The methodology used is a case study of a company in which the process of application of the VSM has been thoroughly analyzed. A team created to improve the productive system of a manufacture for plastic casings for mobile phones has carried out this application.

The research shows that the VSM is a valuable tool for redesigning the productive systems according to the lean system. Nevertheless, there are some key points for the establishing teams that have to take into account, as follows: the time and training resources spent, the use of suitable information systems and a suitable management of the application phases.

The conclusions of this research can be reinforced by the monitoring of the application process in more company cases.

The conclusions of this research are useful for future practitioners, so that they may bear in mind the different aspects of planning projects for redesigning productive systems by using VSM. On the other hand, these conclusions can also be useful for the academic field in order to enhance the theory of VSM.

The paper is a contribution based on practical references according to a thoroughly monitoring of a successful case in establishing VSM.