Research on optimization and simulation of sand casting production line based on VSM

Abstract

Purpose This paper aims to provide feasible countermeasures for the application of lean manufacturing in automatic sand casting workshops to optimize production line balance. Design/methodology/approach A production line balance optimization model for sand casting workshops is proposed. The value stream mapping (VSM) approach is applied to diagnose the problems in the production process. An optimization scheme is established based on eliminate, combine, rearrange, simplify and increase theory and Kanban management method. Further, simulation is done to compare current VSM and future VSM. Findings After implementing the proposed model, findings indicated that the idle time of equipment was effectively reduced, the line of balance of the production line was increased by 44.7%, the production lead time was shortened by 60.3% and the production capacity was increased by 50.0%. Research limitations/implications Application of the optimization model in this study is limited to sand casting workshops that have realized automatic or semi-automatic production. Originality/value This paper provides an optimization model for the implementation of lean manufacturing in sand casting workshops and provides a reference case that reflects the actual application of lean manufacturing tools in a real situation.