Value Stream Mapping (VSM) is a key tool in Lean Manufacturing (LM) that helps identify opportunities for process improvement. This research aims to propose an integrated method using LM tools (such ...as Kanban, VSM, Pareto chart, and Supplier Input Process Output Customer) and Arena simulation to improve the productivity of the production line through reducing lead time, inventory time, including Raw Material (RM) time and Work In Progress (WIP) time and enhancing Process Cycle Efficiency (PCE) ratio. To begin the process, a Pareto chart is employed to identify the main product of the organization. Subsequently, a current VSM is constructed to identify any waste in the production line. The Kanban tool is then used to propose appropriate remedies to improve the manufacturing process. To validate the efficiency of the production capacity in future VSM, Arena simulation is executed by determining Takt Time. Lastly, a future VSM is formulated based on the suggested improvements, and an appraisal is conducted to provide recommendations for prospective enhancements. A real case study of a furniture company in Vietnam is performed to demonstrate the effectiveness of the proposed method. The results reveal impressive benefits, including a 92% reduction in lead time and a corresponding 92% increase in PCE. Additionally, there is a substantial reduction of around 90% in WIP time, while RM time is completely eliminated, resulting in a 100% reduction. These findings highlight the efficacy of the proposed approach and the importance of VSM and other Lean tools in achieving process optimization.
Product development (PD) is a broad field of endeavor dealing with the planning, design, creation, and marketing of a new product. This revolutionary research domain has become of paramount ...importance to beat the competition for multidisciplinary products which are larger in size and have a longer development time. The main focus of this article is to exploit lean thinking concepts in order to manage, improve and develop the product faster while improving or at least maintaining the level of performance and quality. Lean thinking concepts encompass a board range of tools and methods intended to produce bottom line results however, value stream mapping (VSM) method is used to explore the wastes, inefficiencies, non-valued added steps in a single, definable process out of complete product development process (PDP). This single step is highly complex and occurs once while the PDP lasts for 3–5 years. A case study of gas turbine product has been discussed to illustrate and justify the use of proposed framework. In order to achieve this, the following have been performed: First of all a current state map is developed using the Gemba walk. Furthermore, Subject Matter Experts (SMEs) brainstormed to explore the wastes and their root causes found during the Gemba walk and current state mapping. A future state map is also developed with removing all the wastes/inefficiencies. Besides numerous intangible benefits, it is expected that the VSM framework will help the development teams to reduce the PD lead-time by 50%.
Despite the relatively extensive literature on VSM, limited reflection has been reported regarding how managerial proceedings actually put VSM into practice. This research therefore investigates ...these issues as part of the overall lean philosophy and in correlation with some of its main tools. Five hypotheses and three complementary research questions were formulated and tested using a combination of descriptive statistics and Pearson correlation, 2-Sample proportion, one-way ANOVA, 1-Sample t-tests and Tukey-Pairwise comparison tests. Data were collected through a survey questionnaire responded by 168 manufacturing organisations worldwide. The results establish, among other 'soft' aspects; (1) whether organisations that have adopted lean have also employed VSM as an essential tool to identify waste, (2) the position that VSM normally takes in the time frame hierarchy of lean implementation, (3) the complexity of VSM implementation in terms of easiness and time taken for training when compared to other lean tools such as TPM, JIT and Jidoka, and the (4) critical success factors and barriers for the VSM implementation. A conceptual framework to support the implementation and management of VSM is developed through the unification of the results obtained. This study supports the very limited empirical research on the implementation and management of VSM.
Value addition and performance improvement are important to deal with increasing local and global market competitiveness. Interventions and automation based on Lean and ergonomics principles have ...strong influence on performance improvement of the production systems. This study focuses on implementation of lean manufacturing and ergonomics principles to improve work environment and performance of the soccer manufacturing production line. Work visualization and value stream mapping (VSM) techniques were employed to identify the opportunities for improvements. Time of value and non-value-added activities is recorded using time study method. Working postures and associated risk factors are evaluated using Rapid Entire Body Assessment (REBA) method. Lean manufacturing principles are employed to minimize wastes and non-value added activities. Similarly, improvements in work environment are made through ergonomics interventions. Various models comprising different levels of lean and ergonomics interventions were evaluated through simulation before actual implementation. The results of the finalized model in terms of decrease in cycle time (8.64 to 7.018 seconds), increase in daily production (20505 to 24176 soccer balls), and improved work environment are evident of performance improvements in all aspects. The integration of lean and ergonomics principles leads to improve the productivity and working environment for workers in soccer ball manufacturing industry.
Lean manufacturing is a profound system designed to enhance every manufacturing industry's efficiency by reducing waste through internationally recognized tools and techniques. Manufacturing ...industries strive to adopt lean concepts to maximize their resources like staff, facilities, materials, and schedules to be economically effective. However, managers face difficulty selecting the appropriate lean tools out of the many available LM tools for successful lean implementation. This study suggests an innovative approach to choose suitable lean tools to maximize these essential resources. Herein the Value Stream Mapping and plant layout are considered for waste identification. Fuzzy QFD and FMEA prioritize the crucial resources concerning the defined wastes and determine the risk associated with each failure mode's sub-element for lean application. It saves time by analyzing only the most critical resources for a successful lean implementation since its focus only on the most important resources. The applicability of the proposed approach is demonstrated through a case study of an Ethiopian shoe manufacturing firm. With the aid of future state plant layout and value stream map, total cycle time is reduced by 56.3%, lead-time is reduced by 69.7%, materials transportation distance and transportation activities are reduced by more than 75%, and workers required are reduced from 202 to 200.
Given the rise in demand for online, graduate degree programs there is a need to guide program planning and evaluation professionals within institutions of higher education to utilize continuous ...quality improvement (CQI) strategies. Using principles of design thinking and CQI, the purpose of this case study was to describe a CQI project that sought to develop a better understanding of adult students’ experience progressing through their plan of study in an online doctoral program. As part of the CQI project, value stream mapping (VSM) was used to gain visibility and perspective on the actions required by faculty and staff to guide students through their plan of study. The VSM process provided information that led to conversations that furthered the CQI efforts and led to changes in the adult education program that would benefit all students. Improvement processes that lead to better quality and more positive experiences for users are valuable. This case study demonstrates the processes, challenges, lessons, and future directions in the use of VSM to better understand online graduate programs designed for adult learners.
•In adult graduate education, faculty and staff who plan programming want suitable curricular and student support initiatives.•Case study research can provide descriptions of appropriate quality improvement practices to inform decisions about adult education planning.•Value stream mapping was used to make visible what was hidden about the student experience for faculty and staff to consider.•Adult students’ experiences in graduate school can be confusing, therefore communicating in the right way at the right time is important.•Consideration of equity, effectiveness, and empathy for students, as well as faculty and staff, are also needed to support high-quality graduate education.
The sales market requires both the highest quality of offered goods and satisfactory prices for the buyer. In addition to the reliability of the important aspects are also the time of order ...fulfillment, reliability, readiness to act around the clock, and service of sold goods after their sale. In the production and confection of conveyor belts, the priority is a customer who, having strictly defined product requirements, also has individually focused goals. To meet these aspects, you need to look after the product both during its production and after. The products of this industry are specific, so that they can be used, after sales service is often required to be installed at the customer and possible actions to maintain their good condition during operation. The article analyzes selected production processes of transmission belts to identify disturbances. The analysis uses the value stream mapping method. Then, improvement methods were proposed.
The growing development of the building industry and the significant contribution of the construction industry to global energy consumption and CO2 emissions demonstrate the need to apply techniques ...such as lean techniques aimed to reduce environmental impacts by reducing wastes. The present study, using lean techniques has tried to improve the processes of production, transportation, and erection of pre-fabricated steel frame (PSF) components in terms of the energy consumption and CO2 emissions. In this regard, value stream mapping (VSM), just in time (JIT), continuous flow, and total productive maintenance (TPM), as four lean techniques, are used aimed to identify and eliminate processes’ wastes and improve the resource efficiency. To assess the impact of applying lean techniques, the life cycle assessment (LCA) methodology outlined in the ISO 14040 is used. The results indicate that the energy consumption and CO2 emissions are reduced by 9.2% and 4.4%, respectively, that shows the ability to improve the environmental performance of the installation of PSFs by using lean techniques.
•Installation of pre-fabricated steel frames (PSFs) of residential buildings is studied.•Environmental impacts of installation of the PSFs are assessed based on ISO 14040.•Lean techniques are applied to reduce environmental impacts of the installation of PSFs.•Applying lean techniques for installation of PSFs reduces the environmental impacts.•Annual energy consumption and CO2 emissions were reduced by 9.2% and 4.4%, respectively.
Complex product and production systems often result in high variability in the production flow, prohibiting the sustainable implementation of lean practices. In this paper the authors introduce a ...PDCA cycle to analyse and reduce variability in value streams. The value stream is divided into zones, which are then qualified as stable or unstable. Lean practices can be applied in stable zones, unstable zones remain expert-driven. Measures are introduced to reduce variability in unstable zones with the ultimate target, to turn them into stable zones, extending sustainable lean activities in the value stream, step by step. An IT system is developed to acquire, process and visualise the vast amount of data to provide structured information for experts and management for the reduction of variability in production.
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