Abstract
The importance of lean manufacturing concepts has been discussed many times over the few decades. The most important elements in lean manufacturing practices are value stream mapping (VSM), Kaizen events, load leveling (heijunka), etc. In this case study, a real-world clock assembly simulation has been used to study the performance improvement in terms of production flow and lead time after introducing lean concepts. In each round of simulation, the lean concepts have been introduced one by one and performance metrics were recorded. After implementing the concepts, the productivity was improved enormously. So, this simulation study emphasizes the importance of continuous improvement of production flow through lean concepts in a real production setting.
Highlights
Lean is defined as “a philosophy of manufacturing that focuses on delivering the highest-quality product at the lowest cost and on time” [1]
It is useful to illustrate what the processes are like after detecting the changes needed to be done in terms of current state mapping. This will help to avoid the same mistake multiple times and generate even more efficient ideas about how the arrangement of value stream should be in the future comparing to the current one
In lean simulation round 3, further implementation of Kaizen events was tried like changing the layout, removing the redundant station, combining the workstations, and providing more efficient communication between the operators
Summary
Lean is defined as “a philosophy of manufacturing that focuses on delivering the highest-quality product at the lowest cost and on time” [1]. It is useful to illustrate what the processes are like after detecting the changes needed to be done in terms of current state mapping This will help to avoid the same mistake multiple times and generate even more efficient ideas about how the arrangement of value stream should be in the future comparing to the current one. In lean simulation round 3, further implementation of Kaizen events was tried like changing the layout, removing the redundant station, combining the workstations, and providing more efficient communication between the operators. This helped massively to come up with the future state map
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