Companies have realized that the impact on quality, costs, and manufacturing lead-times are often much higher during the product development phase than during the production phase. Therefore, the need of an efficient development process is essential for the company’s future success. Lean Product Development System (LPDS) is a model for improving product development processes. One method included in LPDS is Value Stream Mapping (VSM), which is a method for visualizing the flow of a product, service or information and then redesigning the process based on lean concepts. However, it remains unclear if VSM and LPDS are applicable to development processes in the aerospace industry. The aerospace industry is unique due to its high investments of a single product, long cycle times and low value adding for individual operations.  

This study aims to investigate to which extent VSM and lean development principles are applicable for visualizing and reducing waste in an aerospace product development process. To examine this, a single case study in the aerospace company Saab AB was conducted. The study has an abductive approach, using both inductive and deductive elements. The study examines relevant theory in a literature study and then explores its applicability in a specific development process in an aerospace context. The data for the study were based on qualitative, semi-structured interviews as well as a VSM event. The empirical findings were analysed and compared to the findings from the literature study, suggesting modifications to VSM supported by the results from a conducted design review. 

The results from the empirical study displays the process and its waste, creating a visualizing tool for discussion, in an aerospace product development process. However, the study also displays obstacles with the use of LPDS and the VSM methods in three key areas: complexity, timeframe and data collection. The area of complexity outlines difficulties in defining the value for the different stakeholders. The area of timeframe mostly affects the VSM event due to the changes in the environment during the long-spun process. The obstacles in the area of data collection led to the use of qualitative data rather than quantitative data. Furthermore, there were difficulties to establish a single takt time for the studied process.  

Overcoming these obstacles in an aerospace development process resulted in suggestions for modifications for the VSM method. The purpose of VSM should be to visualize and qualitatively describe the development processes. Prior to the VSM event, the decisions concerning what process steps and what data metrics to use should be decided. Since it is not possible to describe the studied process using one single takt time, a suggestion is to divide the takt time in two separate takt times, facilitating the visualization of customer needs. The last suggested modification is to perform the VSM on different levels, starting the analysis on a higher level and then focusing on the process with the highest potential for waste elimination.