Value Stream Mapping to Improve Workplace to support Lean Environment

Ahmad Nur Aizat Ahmad,Norafifah Husin,Md Fauzi Ahmad,Te Chuan Lee,Rohaizan Ramlan,Mustaqqim Abdul Rahim,M.N Nik Hisyamudin,Md J Mohd Azlis Sani,K Amir,T.A Ahmad Mubarak,I Mohd Rasidi,I Al Emran,M Sofian,Z Izzuddin,M.B Mohd Faizal

doi:10.1051/matecconf/201713500032

Abstract

In recent years, lean manufacturing is being followed by various sectors in order to keep their competitiveness in the global markets. Lean manufacturing plays a vital role in improving the efficiency of operation by eliminating or reducing wastes. Nonetheless, most of small and medium enterprises (SMEs) lack sufficient knowledge or information on the benefits of implementing lean manufacturing. The main objective of this study is to apply value stream mapping, one of lean manufacturing tools, for improving the productivity in a SME by eliminating non-value added activities. In this study, lean manufacturing was adopted at a SME, particularly a food industry. Value stream mapping was served as main tool to identify the wastes and improvement opportunities in production line. Subsequently, different lean manufacturing tools such as Kaizen Burst, one piece flow, and 5S were applied to eliminate or reduce identified wastes. Based on the future state value stream mapping, final results showed that the total operation time and non-added value activities time were successfully decreased from 1993 seconds to 1719 seconds, and 234 seconds to 104 seconds, respectively. The findings of this study indicate that value stream mapping is an effective approach to eliminate the wastes and improve the productivity.

Highlights

Despite an abundance of obstacles, the biggest challenge faced by manufacturer is how to deliver their products or services quickly at low cost but high quality
The ultimate goal of Current State Value Stream Mapping (CSVSM) is to illustrate how a product flow through the value stream, starting from raw materials to finished product
Takt time is defined as the time needed to produce a product to meet customers’ demand

Summary

Introduction

Despite an abundance of obstacles, the biggest challenge faced by manufacturer is how to deliver their products or services quickly at low cost but high quality. A number of approaches have been undertaken using computer simulation, statistical analysis, and lean manufacturing for improving the productivity and efficiency of production line [1]. Lean manufacturing is one of most popular approaches and has been widely implemented in many manufacturing industries around the world. Lean manufacturing is currently becoming more popular in manufacturing industries. It can be seen that lean manufacturing has been developed, growth up, and adopted progressively in many major manufacturing industries in order to remain their competitive in an increasingly global market [2]. The main focus of this approach is on cost reduction by eliminating waste or non-value added activities. The perfect strive of the manufacturing system can be achieved through successful implementation of lean elements [3]

Objectives

Results

Conclusion