Value Stream Mapping Method Research Articles

The integration of dynamic value stream mapping and cost time profile method for optimizing offshore drilling logistic base operations

The research aims to analyze the integration of Dynamic Value Stream Mapping (DVMM) and Cost Time Profile (CT-profile) method for optimizing offshore drilling logistic base operations. The novelty of the research is the implementation of DVMM and CT-profile that implemented in monitoring system INTACTS (Integrated Dynamic value stream mapping and Cost time profile for shore base operation) which is directly connected to shore base material movement recording system. Each successful lift performed in JIT mode will be recorded and its characteristics studied so that it can be applied to other material lifting operations. This research uses data on the lifting operation on July - December 2020. The new method is applied in a logistic system for drilling activity. The research shows that DVSM is suitable to be applied for logistics in off shore base problems since the job and situation are very dynamics.

Enhance Productivity In The Garment Industry Through A Modified Value Stream Mapping Approach

The objective of this study is to overcome problems that occur in the garment industry, the company has tried to develop an agile system to increase productivity in this industry. The garment company that focusses on the production of woven bottoms and outerwear, noted that women's woven bottoms products have the highest demand throughout 2022. However, the company was unable to meet Brand demand of 3.5%. Production data shows defects in products, low quality raw materials, and unstable production processes. A modified Value Stream Mapping (VSM) methodology is use to consider all aspects of production. The results of traditional VSM and Value Stream Analysis Tools (VALSAT) analysis include current state and future state, identification of value added and non-value-added elements during the production process, as well as setting priorities to reduce waste in the production process, especially in inventory (19%), defective parts (17%), and transportation (15%). Based on the VALSAT matrix, Process Activity Mapping (33.5%), Supply Chain Response Matrix (21.6%), and Demand Amplification Mapping (15.3%) were obtained. The findings of this research are Pilot Run, which succeeded in becoming an agile and reliable system during the production process. Through the application of the methodology combined with VSM the results have improved compared to the traditional VSM method. This proves that this method is effective in overcoming takt time, cycle time, man power, and value-added ratio. Limitations of this research were also discussed, including that this research only focused on women's woven bottom products only on the production workflow. Kata Kunci: Agile System, Enhance Productivity, Garment Manufacturing, Lean Manufacturing, Value Stream Mapping.

Good Practices in Implementing the Circular Economy in the Energy Sector – Conversion of Fly Ash into Construction Materials

The support of actions aimed at reducing levels of pollution emissions into the environment requires popularization of good practices, including those involving solutions in the field of the circular economy. These actions are particularly important in sectors of the economy characterized by a high share of total emissions, as their modernization through economies of scale translates into greater environmental benefits. An example of such a sector is the energy sector. The aim of this paper is to identify and characterize selected processes within the activities of the energy sector, where a circular economy approach can be applied, and to assess the implemented solutions. This analysis was carried out using the largest entity in the Polish power sector as a case study. Process analysis was conducted using the value stream mapping method. The identified circular solutions in the process and product areas constitute an important contribution to promoting the activation of economic entities in actions aimed at improving the state of the environment.

Combination of value stream mapping (VSM) method and kanban system to reduce time waste in the production process of making parts for the four-wheel vehicle industry

Fulfilling orders from customers in the automotive industry is a necessity that inevitably causes problems that arise in product delivery to customers due to production delays and decreased production yields. The production process often experiences wasted time in the production process of four-wheeled vehicle spare parts. This research aims to reduce production process time, provide solutions to reduce waste and increase the number of four-wheeled vehicle spare parts produced. This research method uses the Lean Manufacturing (LM) approach by combining the Value Stream Mapping (VSM) method with Kanban system improvements, the application of Root Cause Analysis (RCA), and the Kaizen method. This research found that four factors cause waste in process time, including environmental factors, methods, humans, and machines. This research produces the right solution in the relay out of the Assembly and Final Inspection production processes, as well as the use of the e-kanban system in material and product inventory. The research results have reduced the production process time from 17.10 days to 10.05 days, meaning a decrease of 41.22%. This affected production results which increased from an average monthly production of 42,917 pcs to 60,157 pcs, meaning an increase of 128.65%.

Improving efficiency in green tea production time using lean manufacturing approach with value stream mapping: A case study at PT Candi Loka [Perbaikan efisiensi waktu produksi teh hijau menggunakan pendekatan produksi ramping dengan value stream mapping: Studi kasus di PT Candi Loka

Green tea production activities at PT Candi Loka indicated a time-consuming, which caused process efficiency to be less than optimal. Process efficiency improvements must be made to increase company competitiveness and consumer satisfaction. This research aimed to analyze the efficiency of green tea production time at PT Candi Loka by identifying the processing time required in each production activity, including the time consumption and formulating recommendations for improvement using a lean manufacturing approach using the VSM (Value Stream Mapping) method. There were 30 activities in 6 processes consisting of receiving raw materials, withering, rolling, drying, and packaging. Identification of value streams using the PAM (Process Activity Mapping) tool produced 9 Value added (VA) activities, 19 Necessary but Non-Value Added (NNVA) activities, and 2 Non-Value Added (NVA) activities in the form of delays in the withering and drying processes. In the current state map analysis, the production lead time value was 315.286 seconds. Recommended improvements to eliminate delays in the withering process were to set up the rotary panner machine earlier and increase the number of supervisors, while to eliminate delays in the drying process were to implement a piece rate system. Increasing efficiency was also carried out by improving NNVA activities by adding weighbridge facilities and using a conveyor system. The future state map proposed by implementing recommended improvements resulted in an increase in production time efficiency to 222.356 seconds and an increase in the process cycle efficiency value from 58.95% to 84.85%.

Identifikasi Non-Added Value Activity Dalam Proses Pemeriksaan Substantif Permohonan Paten Menggunakan Value Stream Mapping

The process of substantive patent examination which is complicated and takes a long time is one of the reasons the inventor is "reluctant" to apply for a patent on his invention. This research was conducted using the Current State Value Stream Mapping (CSVSM) method, which began with the creation of a process flow map with the cycle time of each activity. It is known that most of the activities are value added activities. However, there is 1 activity that is required but not added value, namely the activity of verifying the technical field of application documents; and 1 non-value-added activity, namely initialing the Patent Granting letter. The number of waiting/delaying incidents is a waste in the process of substantive examination of patent applications caused by: (a) employees generally do double work; and (b) the absence of SOPs in each sub-process/sub-activity in the process of substantive examination of patent applications. Proposed improvements are submitted in the Future State Value Stream Mapping (FSVSM). As a result, lead-time can be reduced to 11 days, which was originally 26 days; and Process Cycle Efficiency which was originally 19.23% increased to 45.45%

Identifying and Prioritizing Waste in OCTG Production Lines Through Value Stream Mapping and Borda Count Method

Identifying and Prioritizing Waste in OCTG Production Lines Through Value Stream Mapping and Borda Count Method

Pengukuran Efisiensi Proses Produksi Castable Guna Mengidentifikasi Wasting Time di PT Benteng Api Technic

PT Benteng Api Technic was founded in 1997 and produces refractory bricks, refractory cement and various refractory materials. Refractory cement or castable currently still uses a pre-order system before the production process is carried out. During observations for seven days with 38 observations, there were activities that were felt to be less efficient, then the value stream mapping method was carried out to streamline waste. The result is a defect when the production process is finished, there is a repetition of the production process because it does not pass the feasibility test, processing because a lot of leftover material falls in the bagging section and the material is no longer used. Waiting is the average part of weighing materials/products of 1.54 seconds (waiting for the material composition recipe and weighing platform trouble/error). Material mixing section with an average/product of 1.82 seconds (waiting for machine repairs due to leaking air duct). Total production lead time is 3396 seconds. Once the waste is identified, the next step is to eliminate the activity by testing data adequacy and testing data uniformity. The results of the analysis of the castable production process contained 2 analyses, the first analysis by reducing activity time with an average total time of 3285 seconds/44 cement and the second analysis by reducing and eliminating the cement weighing activity in the bagging section with a total time of 2873 seconds/44 cement

Lean Manufacturing Analysis to Minimize Waste on The Production Process

Improvements to eliminate or reduce non-value added activities that cause waste with Lean Manufacturing analysis on CV ABC. Lean Manufacturing is a continuous effort to eliminate (waste) and increase value add (value added) products (goods/services) to provide value to customers (customer value). Objective This research is to determine the factors that cause waste in the production process and to give proposal on company method minimize waste which has been identified. Data in this research are quantitative and qualitative data. Primary data processing in the form of standard time calculations took 30 data, which means 30 batches of fish roulade production. Lean Manufacturing Approach carried out by analyzing the flow of information and the flow of goods using the Value Stream Mapping method. Waste Which dominant happen that is time waiting, unnecessary movements and processes it is not in accordance with. Waste of time waiting occurs in process steaming. Waste time wait on process production can be minimized by adding production facilities which can reduce the dough waiting outside the machine steaming. Waste movement which no need can minimized by increased supervision from superiors as well as providing firm action to workers. Waste for non-compliant processes can be reduced by clarify standard operation Which applies in company and stick it in every production process, as well do maintenance machine in a way regular so that performance machine always deep conditions which good. Reduced time to reduce lead time ie amounting to 37.78 minutes. This time is obtained from subtraction the process of taking spices, weighing flour and vegetables as well as preparation and maximization activities process draining with addition facility. Matter this result change time leads time production from 674.44 minutes to 636.66 minutes.

A Review of Literature on Lean Manufacturing Tools and Implementation Based on Case Studies

This research focuses on reviewing the Lean Manufacturing (LM) implementation which is widely applied in the manufacture company to overcome or reduce waste. The aim of this article is to find out more about the influence on the industry sector. This research was developed by collecting research from indexed databanks of Scopus, Science direct, ResearchGate, etc. This review study is significant to identify the application of lean manufacturing in dealing with waste through implementation into several case studies. A total of 24 articles were selected, taking into account criteria such as keywords, article titles and publications of international publishers, which were selected through a systematic process. This study found that the application of lean manufacturing is a method that brings many advantages that work by minimizing losses and waste, and the Value Stream Mapping method is more often used as part of several Lean Manufacturing techniques to identify and analyze the occurrence of waste while providing solutions that lead to improvement. process and cost reduction.

Improve Productivity and Quality Using Value Stream Mapping Method. A Case Study in LED Bulbs Factory

The business environment for businesses is expanding, and at the same time, competition is also increasing. This creates opportunities for businesses to grow, while also containing challenges that threaten businesses. This research paper proposes to use the Value Stream Mapping (VSM) method in the LED bulb manufacturing process to analyze, improve, and enhance the productivity and quality of LED bulbs. The results of the study showed that productivity increased by 5% (the cycle time of the light testing process went from 15 seconds to 4.85 seconds) and the defect ratio decreased from 3% per month to 0.5% per month. This research model can be used in different industries to improve business efficiency.

Streamlining logistics flows with lean tools using TX Plant Simulation software support

A critical factor in the manufacturing industry is waste and losses in individual operations and processes. The expansion of elements of lean production, such as the pull system with the interconnection of key technologies, brings new elements of production planning and control. Thanks to new technologies, many more possibilities exist to uncover potential bottlenecks. Simulations and modelling bring new possibilities for experimentation in the virtual environment of prepared systems or devices without directly disturbing the functioning system. The presented article deals with the issue of applying lean approaches in finding optimal solutions within logistics flows. The aim of the article is to define and test the potential for streamlining logistics flows with TX Plant Simulation software support. The research and empirical part of the study was solved based on a rigorous analysis of the initial situation in a specific company for the selected product group, as the Value Stream Mapping method was used for the analysis. A simulation model of a real line was created in the TX Plant Simulation software with the help of the Value Stream Mapping library for value creation, which is part of the software. The goal was to find out possible waste within the logistics flow, and its causes and propose the necessary steps to eliminate the waste.

DEĞER AKIŞ HARİTALAMA YÖNTEMİ VE BİR İMALAT İŞLETMESİNDE UYGULANMASI

Teknolojinin gelişimi, birçok sektörün daha geniş bir kitleye hitap etmesine olanak sağlamaktadır. Bu durum, firmalar arasındaki rekabeti artırmakta ve daha fazla müşteri ile etkileşime geçmelerini gerektirmektedir. Çeşitli sektörlerde faaliyet gösteren şirketler, kaliteyi artırmak, maliyeti düşürmek, üretimi verimli hale getirmek, israfı azaltmak, hurda miktarını düşürmek ve müşteri taleplerini zamanında karşılamak için yalın kavramını benimsemektedir. Yalın üretim teknikleri, aynı hedefe hizmet etmelerine rağmen uygulanmaları açısından farklılık göstermektedir. Yalın üretim yöntemlerinden biri olan Değer Akışı Haritalama (DAH) yöntemi, üretim sürecinde akışı bozan darboğazları ve tüm süreçle ilgili gerekli bilgileri görsel olarak sunmaktadır. Ayakkabı yan sanayisinde üretim yapan bir firma tarafından yapılan bu çalışmada; değer yaratmayan faaliyetleri ortadan kaldırarak üretim süresini kısaltmak ve müşteri taleplerini daha hızlı karşılamak amaçlanmaktadır. Bu amaç doğrultusunda ürün ailesi seçimi için ABC analizi kullanılmış ve sonrasında DAH yöntemi uygulanmıştır. Sünger ana malzemesiyle üretilen ürünler için mevcut durum haritası çizilmiş ve iyileştirme fırsatları belirlenmiştir. İyileştirmelerin yapılabilmesi için gelecek durum haritası ve spagetti diyagramı çizilmiştir. Gerçekleştirilen iyileştirmeler sonucunda üretim akışı 32,25 günden 23,5 güne düşürülmüştür. Ayrıca, malzeme dolaşımı 262,25 metreden 233,8 metreye indirilmiştir.

Implementation of Lean Service Approaches to Improve Customer Satisfaction and Sustainability of Health Equipment Procurement Process at Hospitals

Purpose: This study aims to identify the waste that occurs in the process of procuring medical equipment and provide suggestions for improvements to reduce waste in achieving customer satisfaction. Methodology/Approach: This study uses a lean service approach with the value stream mapping (VSM) method which is in the refinement stage combined with the Kaizen method. Findings: This research found waste that occurs in the process of procuring medical devices called creating a project and admin invoicing. Increased customer satisfaction with evidence of a decrease in the number of complaints by 44.5%. Meanwhile, the lead time for the procurement of medical devices decreased by 34.2%. Research Limitation/implication: This research has several problem formulations that occur in the manufacturing industry in the process of procuring medical equipment. This research will identify the types of waste that occur in the process of procuring medical devices and find solutions to reduce waste in achieving customer satisfaction so that there will be continuity in the procurement of medical devices. Originality/Value of paper: Shorten the time to procure medical devices by using a lean service approach combined with the FGD method with experts in the logistics and health fields. Besides that, it also uses several Kaizen methods such as Fishbone, FMEA, and 5W+1H, and its control uses SOP. Category: A case study

Lean Manufacturing Analysis Using the Value Stream Mapping Method in the Paving Block Production Process at PT. SMX East Java

PT.SMX merupakan perusahaan yang bergerak dibidang pengecoran dan produksi paving block, untuk proses pembuatan paving block membutuhkan waktu 1 hari dari bahan sampai selesai. Namun selama proses produksi terdapat beberapa kendala yang menyebabkan kegiatan produksi tidak selalu berjalan dengan lancar. Sebab, ada pemborosan selama proses produksi, masalah utamanya adalah Lead Time. Tujuan dari penelitian ini adalah meminimalkan pemborosan dengan menggunakan value stream mapping . Pada penelitian ini akan menggunakan value stream mapping dan data yang digunakan berdasarkan penelitian langsung, setelah data diperoleh dilakukan analisis peningkatan nilai VA pada Current State Mapping sebesar 1,345 menit, setelah dilakukan perbaikan menjadi 345 menit, NNVA yang 337 menit setelah dilakukan perbaikan menjadi 227 menit, dan nilai NVA yang sebelumnya 90 menit menjadi 25 menit. Minimisasi tertinggi terdapat pada proses penyimpanan sementara di penyimpanan Paving block setelah dicetak sebesar 900 menit dan penyebab utama pemborosan persediaan karena gudang penyimpanan perlu ditata ulang.

Analisis Waste Pada Proses Produksi Sosis Ayam Dengan Pendekatan Lean Manufacturing Di PT. BI

PT BI is a food manufacturing company that produces several processed chicken products, one of which is chicken sausage. In the chicken sausage production process, some of waste was found, so a way is needed to improve productivity with the Lean Manufacturing approach, the Value Stream Mapping method. The purpose of this research is to identify waste and provide suggestions for improvements to the chicken sausage production process. From this research, it was identified that five workstations waste, in the Screening area, Preparation, Mixing & Stuffing, Link Cutting, and Multipack Packing. From the results and proposed improvements, it was found that the difference in processing time between the current time and the proposed time was 2.18 hours also the difference in the proposed process line efficiency was 1.72% greater than the current line efficiency. Keywords: Lean Manufacturing, Value Stream Mapping, Waste.

Application Method of Value Stream Mapping to Increase Competitiveness in a Textile and Apparel Company

The textile and apparel sector is one of the most relevant and representative in Peru, due to its tradition and its contribution to the national economy. In recent years, however, it has had to become more competitive, largely due to the entry of international textile product suppliers into the local market. Therefore, companies that comprise this sector must adopt tools that will allow them to increase their productivity. In view of this situation, this research aimed to develop and implement an application model using Value Stream Mapping (VSM) in a textile and apparel company that manufactures garments for export, demonstrating at the same time that VSM is the best tool to visualize the entire supply chain in a single document. It also makes it possible to identify areas of opportunity, perceive the contribution of direct value to the products, distinguish forms of waste, and identify bottlenecks. The methodology adopted for the research is a case study, due to the use of various sources of information, including personal and documentary sources, and the conditions for its development. The results show the determination of the optimal takt time (1060.08 s), and the reduction in the lead time from 20.87 days in the current state map to 16.7 days in the future state map, thus contributing to the improvement of the company’s competitiveness.

PEMETAAN PENCIPTAAN NILAI PADA AKTIVITAS PENGADAAN DAN PENJUALAN SKRAP LOGAM KALENG MENGGUNAKAN VALUE STREAM MAPPING UNTUK MENGURANGI WASTE DI PT ANISA JAYA UTAMA

Industrialization is an alternative development model needed by the country to spur economic processes. Apart from accelerating the economy, the development of industrialization also has impacts that need to be watched out for, including the presence of a waste industry. One of the companies that manages the waste, namely PT. AJU is also a service company for the procurement and sale of metal waste (metal scrap) in Karawang. The metal scrap studied is canned metal scrap, which is wasteful in the procurement and sales process. So that efforts are made to minimize the waste that occurs. This research uses the Value Stream Mapping method with VALSAT analysis. Based on the research results, the most common types of waste are waiting (28%), inventory (24%), and movement (20%). Then the mapping tools that will be used based on the results of converting the questionnaire scores into the VALSAT matrix are Process Activity Mapping (33%), Supply Chain Response Matrix (20%), and Demand Amplification Mapping (17%). The Value Added Ratio (VAR) before the repair has a value proportion of 3%, while after the repair analysis the VAR value becomes 9%.

Implementation of Lean Healthcare for Reducing National Health Insurance Out Patient’s Waiting Time using Value Stream Mapping Method

Waiting time is one of quality standard in health services. The waiting time for national health insurance outpatients in Sosodoro Djatikoesoemo Hospital in Bojonegoro obtained an average monthly achievement of around 59.79% less than the standard from ministry of health’s regulation (80%). This study aimed to reduce patient waiting time using value stream mapping analysis and purpose the future stream mapping. This was a quantitative descriptive study using a cross-sectional design using Value Stream Mapping analysis. The sample was obtained by purposive sampling of 90 outpatients under national health insurance in Sosodoro Djatikoesoemo Hospital in Bojonegoro. The data was collected by using the observation table. The results found that two waste were found during outpatient flow including waiting and extra processing. In addition, the analysis obtained a Value Added Ratio (VAR) of 23.61% indicating that the service was not efficient compared with the provisions of Process Cycle Efficiency (> 30%). The future Stream Mapping was proposed and indicated a decrease in waiting time which was originally 99.21 minutes to 58.16 minutes. The possible improvement is the development of an electronic patient eligibility certificate of national health insurance where this improvement is useful in reducing patient waiting time by 41.05 minutes or around 41.37%. The management can consider to develop an electronic patient eligibility certificate in order to make the service delivery in out patient more efficient.

Design of Integrated Warehouse Control Tower (WCT) Digitalization by the Internet of Things Architectures

The problem that often occurs in information systems, especially in the logistics process, is improper management because the machine is not connected to inventory control and not integrated with the operator, so it takes a long time to analyze errors in the logistics process. This study develops warehouse logistics control information to speed up and accurate inventory processes. This study designed the Warehouse Control Tower (WCT) as a strategic development based on Wireless Sensor Network that is connected to a warehouse system and integrated with a computer connected to the RFID (Radio Frequency Identification) system, AI (Artificial Intelligence) cameras, and barcodes. Value stream mapping is used to map the process flow of warehousing activities and information flow at the level of the total warehouse process flow. Overall, the results of the analysis using the value stream mapping method indicate that the process flow using RFID and Artificial intelligence is more efficient than before implementation.