Kanban and value stream mapping analysis in lean manufacturing philosophy via simulation: a plastic fabrication (case study)

Abstract

This article is a practical study focusing on three lean manufacturing techniques, which are Kanban production system, setup time reduction, and total productive maintenance (TPM) in a plastic fabrication industry. Nevertheless the methodology can be simply expanded to other industries as well. Kanban is implemented as the main subject for just–in–time (JIT) production systems, while value stream mapping (VSM) is utilised to focus more on the streams in the production processes. The three main causes for work–in–process (WIP) are selected based on the cause and effect diagram in the company. Based on simulation and the results obtained from ANOVA, Kanban and TPM are recognised as the two most significant techniques in comparison with the setup time reduction technique which has the least significance. Furthermore, the study signifies that the Kanban–TPM system widely stimulates the reduction in both lead time and WIP inventory. Finally, the new VSM of the company signifies the alleviation of information exchange and paper works between various departments engaged in the process in comparison to the prior situation.