Papers by Keyword: Value Stream Mapping

Abstract: This study investigates the implementation of lean tools to enhance process cycle efficiency and reduce production lead time by at least 10% in a case study of pipe sleeve fabrication at one of manufacturing company in Indonesia. Improving production efficiency is a critical investment for manufacture sustainability and competitive advantages. The application of lean tools, such as value stream mapping and pareto analysis, can help reduce process inefficiencies by eliminating non-value-added activities, such as machine breakdowns, waiting, and material handling. The results demonstrate that the implementation of lean tools can increase Process Cycle Efficiency (PCE) from 39.76% to 51.40% and reduce Manufacturing Lead Time (MLT) by 22.63%. This case study provides insights into how lean tools can be applied to improve productivity in manufacturing processes. Lean tools can be implemented across various manufacturing industries to enhance their productivity. Broader implications of implementing lean method suggest that companies can enhance productivity, reduce cost of production, improve quality, and ultimately increase their competitive advantage in the market.

Abstract: To maintain its competitiveness, the Indonesian CPO industry must apply lean techniques such as value stream mapping (VSM) that can be utilized to increase the process efficiency. While there have been several studies which attempted to apply VSM techniques to the CPO industry, the results of these studies have not been summarized and compared. This paper aims to summarize the findings of previous VSM studies in Indonesian CPO industry and provide the directions for future researches. In this study, the brief literature review is applied in which the relevant articles are reviewed according to the scope of study, approach or method, and types of identified wastes. Various types of wastes found from the initial stage (FFB reception) to the final stage (CPO storage). The average process cycle efficiency score indicates the requirements for improvement actions. Recommendations for future VSM researches include the scope of the process stages studied, process mapping for future condition, and the requirements of green and sustainability aspects.

Abstract: The main aim of Lean Manufacturing concept is to produce more with less: space, stock, workforce and time. The companies that along the years implemented Lean Manufacturing, reached a spectacular development, mainly because with the same workforce and financial resources, succeeded to increase significantly their profit (some reached up to 300-400% increase). The strength of Lean concept is the calculation of value of product for the final client, considering each stage of manufacturing. Therefore, the main aim of this paper is to analyze and improve the manufacturing flow of a component, from the system entry point to its exit using Flow Mapping and Value Stream Mapping. After all the actions on improving the flow, the activities without added value decreased with 15.92% and the lead time with 15.61%

Abstract: Increasing concern over the resource consumption and utilisation alongside of any manufacturing process decides the sustainability of the product. Many contemporary organisations due to stringent government regulation and policies now focus on management of waste generated across their units. Value Stream Mapping (VSM) generally focuses on reducing task time and thereby reducing monetary over heads. From the environmental perspective, the type of waste produced is important because of the difference in level of toxicity and environmental impact. This work focuses on imbibing environmental waste into the lean method of value stream mapping. The proposed integrated model was implemented in a case organisation and environmental impact was computed. The developed model can be used by stake holders and represent environmental impact at individual process and product levels to align organisation practices with strategic objectives for waste reduction.

Abstract: The growing context of globalization permanently increases pressure on the construction companies to improve their performances in order to resist to the constraints of competitiveness in the international market. It has become ineluctable to look for introducing a new alternative capable of bringing creative improvement to the traditional production system. This paper will relate mainly to the most relevant management techniques in the construction industry, and more specifically, the lean construction concept. Initially, we will determine the main characteristics of the construction industry compared to the manufacturing industry according to three levels: on-site production, one of a kind projects, and complexity. Subsequently, we will focus our attention on the main sources of waste in the construction industry. Finally, a rigorous comparative study will be carried out to show the contribution of the lean construction tools in the promotion of traditional construction especially at the level of the following factors: Creating value and eliminating waste; Planning and mutual coordination; Site organization. Lean construction as Last Planner System (LPS), Value Stream Mapping (VSM), Just-in-Time philosophy, Visual management (VM) and 5S have shown a great ability to improve the traditional production system through waste reduction, encouraging people involvement, ensuring a pull flow production, and promotion of a continuous improvement philosophy.

Abstract: The research is designed to reduce production lead time using Value Stream Mapping (VSM). The purpose of this lean tool is to uncover the wastes in supply and production process by separating value-adding and non-value-adding steps first and then reduce non-value added steps. A map shows the current state of the operation is drawn first using the time and flow data. By this non-value added actions are recognized and the waste of time and resources between the steps are also identified. To reduce lead time and streamline the process the map is analyzed. The lead time can be reduced by taking some actions or applying some lean tools. Value adding time in the whole process increases and the process production lead time decreases after reducing the wastes. A future state map is made with new and improved processes. Future state map makes the reformed process more effective and more efficient. It comprises the developments through some value stream symbols used only for this mapping. Bata, a leading shoe company was selected for this research work. To draw the current state map, data was collected from the floor. The wastes identified then which were waiting, motion, inventory & transport. The lean tools that were suggested to apply for reducing these wastes were Kanban, Kaizen, Safety Stock and some manpower adjustment. Kanban is a method to achieve JIT, a system to control the logistical chain from a production point of view and also an inventory control system. Safety stock represents an inventory hedge against problems such as downtime, to protect the system against sudden fluctuations in customer orders or system failures. And Kaizen is the small and continuous improvement methods. The result of the research was quite remarkable as this decreases the lead time by around 8% and increases the capacity by 8.8%. It is feasible to use value stream map in the current situation.

Abstract: The paper deals with the issue of increasing production processes efficiency, stabilization and also increasing the labor productivity through the implementation of lean manufacturing principles. Waste reduction and increase in the efficiency of manufacturing processes is a long-term, systematic matter, which requires the utilization of appropriate methods and methodologies. Therefore, this papers points out the growing importance of utilizing certain methods and principles which lead to the reduction of inefficient costs. The Value Stream Mapping (VSM) method, which can quickly point out existing reserves and provides an effective platform for the evaluation of lean manufacturing and Overall Equipment Efficiency (OEE) method, which evaluates the effectiveness of used manufacturing equipment are, both analyzed in detail.

Abstract: The purpose of this study is to develop a value stream mapping for a production in an aircraft manufacturing company. The process begins with creating a current state map and understands the production flow and the current cycle times. This provides the information needed to produce a future state map. The goal is to identify and eliminate the waste, which is any activity that does not add value to the final product, in the production process. In order to collect the information needed, the study was conducted within the production facility to enable the researcher gained knowledge and familiarized with the production flow and the activities being performed at the shop floor. Parameters such as cycle times, down times, work in process (WIP) for inventory and material, and information flow paths were recorded. This information will enable the researcher to visualize the current state of the process activities by mapping the material and information flow and looking for opportunities to eliminate wastes. ARENA simulation software package was used to simulate and analyze the process flow and times. Result from the analysis shows that there are areas where the company can further improve their production system. The results show the improvement of the cycle time up to 22% based on the new proposed arrangement of the layout. Therefore the propose layout will be guided to the company in order to improve their production.

Abstract: This article describes the analysis of the manufacturing enterprise (machine shop). We propose the methods and tools of optimization in order to build a "lean" management system. The purpose of constructing this management system is to eliminate losses, reducing costs, increasing productivity. We used SWOT-analysis tools, VSM (value stream mapping) and discrete simulation (Plant Simulation).

Abstract: CTC Express is the leading domestic company in delivery service and wants to improve their business efficiency by establishing lean management in the shop floor activities. Lean management is generally adopted by the manufacturing industries as a significant technique to reduce waste and operation costs. This paper investigates the continuous improvement through value stream mapping, begins with describing the current situation and proposes the future condition. Several improvements were implemented in the company such as the transformation of automation process, better result in visual control and standardization processes. The new proposed system has shown being able to reduce the works of loading/unloading and in the same time to increase the performance of material handling in each cycle time.