A framework for achieving lean orientation in complex production value streams

Abstract

The purpose of this paper is to present a framework for achieving lean in manufacturing organisations. Value stream mapping (VSM) is a commonly used tool for achieving lean orientation in a manufacturing setup. It is a very useful preliminary tool to gain useful insight to identify lean wastes. However, there are many cases, where VSM has to be supported by some additional tools for analysis. Examples of such production systems include complex production systems such as converging, diverging flows or production systems where complete products (assemblies made up of several components) are getting manufactured. There are also situations where lean practitioners need additional insights into the financial health of the value stream in terms of monetary measures, e.g., revenue, costs, profitability, etc. This research paper suggests a framework for such production scenarios. The proposed framework combines value stream mapping with discrete event simulation (DES) and lean box score. The framework is demonstrated through a case of a capacitor manufacturer.