Value Stream Mapping Approach Research Articles

Multiobjective design of automated order fulfillment systems: A case study for an existing surgical complex

We present a case study that introduces a systematic framework for designing an automated guided vehicle (AGV) order fulfillment system. The multi-stage framework integrated discrete event simulation (DES), super-efficiency data envelopment analysis (S-DEA) model, and Design of Experiments (DOE) methodologies for the design of an AGV system in an existing large-scale surgical complex within a comprehensive hospital in Singapore. Performance metrics derived from this model were consolidated into a single relative efficiency score using the S-DEA model. This efficiency score was then utilized in a DOE methodology, combined with a post-hoc model selection process, to robustly identify appropriate models for evaluating alternative system designs. The proposed framework optimizes AGV deployment by first identifying opportunities for AGVs to add value within the surgical system through a value-stream mapping approach. It then derives the optimal system design by balancing cost efficiency, manpower reallocation, and order fulfillment rates, facilitated by the S-DEA model augmented with the DOE approach and post-hoc model selection. Application of this framework to the surgical complex revealed several insights that can significantly enhance AGV efficiency prior to actual deployment. However, a key limitation of this case-study-based approach is its limited generalizability across different systems. Despite this, the methodology provides a robust foundation for AGV system design in similar healthcare environments.

Lean manufacturing in agriculture: adapting the value stream mapping approach for farm management

Lean manufacturing in agriculture: adapting the value stream mapping approach for farm management

Manufacturing Lead Time Using the Value Stream Mapping (VSM) Approach in the Oyster Mushroom Baglog Production Process

Manufacturing Lead Time Using the Value Stream Mapping (VSM) Approach in the Oyster Mushroom Baglog Production Process

Study on Labor Productivity Improvement Based on Situational Awareness and Improved Value Stream Mapping

This study addresses the issue of poor construction labor productivity, exploring the process and methodology for increasing construction workers’ participation in labor productivity improvement, as well as a situational awareness (SA) development approach for construction workers based on lean construction (LC). A framework for enhancing labor productivity through SA has been developed. A case study approach is utilized to describe the LC improvement process, which includes enhancing construction workers’ SA for waste minimization and process optimization and engaging them in LC with improved value stream mapping (VSM). The labor productivity measurement approach, combined with VSM, is used to evaluate the labor productivity improvement with labor productivity improvement rate, resource efficiency, and flow efficiency. The results demonstrate that the labor productivity of the case project has increased by 24.07%, with 11.54% contributing resource efficiency and 88.46% contributing flow efficiency, indicating a greater increase in flow efficiency. This study fills a research gap in terms of the combination of construction workers’ SA enhancement and the involvement of LC practices to boost labor productivity. Furthermore, this study proposes an SA development approach based on LC at three levels: waste perception, VSM implementation, and labor productivity improvement assessment. This provides new perspectives for leveraging construction workers’ SA to increase labor productivity. The improved VSM approach and labor productivity measurements provide an operationalization of workers’ participation in continuous improvement. This research is of great practical relevance for augmenting the competencies of construction laborers and inspiring them to engage in labor productivity enhancement.

Proposed Maintenance Plan for Maker Machinery with Reliability Centered Maintenance (RCM) Method and Maintenance Value Stream Mapping (MVSM) at PT. XYZ

PT XYZ is a company engaged in cigarette production, where most of the production process uses automatic machines. The problem faced by the company is damage that occurs at any time before the scheduled maintenance interval causes overhaul and replacement or corrective maintenance activities which causes downtime and stops the production process on production machines that have a high average downtime compared to other machines. With these problems, calculations are carried out to obtain maintenance scheduling time intervals. The index of fit is used to measure how well the Weilbull distribution is based on the time to repair data. The fit index value (r) for the Hoper component downtime data is 0.92 or 92%, which means that the Hoper component downtime data can be completed using the Weilbull distribution. Calculation of the time to failure and time to repair parameters uses the Weilbull distribution by finding the intercept (a), gradient (b), shape parameter (α) and scale parameter (β). Calculation of the mean time to failure and mean time to repair using the results of parameter calculations using the Weilbull distribution based on the gamma table results in a mean time to failure of 1054.67 hours and a mean time to repair of 218.18 minutes. Calculation of the inspection time interval on the Hope component for 250 hours or 10 days per month. Analysis of maintenance efficiency using the maintenance value stream mapping approach obtained a maintenance efficiency percentage of 77.5%. Activities that provide added value have a longer time, namely 218.18 minutes. While activities that do not have added value is 63.2 minutes.

Lean Manufacturing Implementation through Value Stream Mapping on Gold Products

The manufacturing process at UBPP Precious Metal Manufacturing Bureau involves many wasteful activities such as manual production records, lack of standardization and digitization, which can lead to lost time and non-conformities if something goes wrong. The purpose of the study is to identify and eliminate wastes in the manufacturing process using Value Stream Mapping (VSM) to achieve lean manufacturing. VSM approach to understand gold manufacturing mapped in the current state map and improvements applied to the future state map. The cycle time in the weight check, cleaning, press and engraving process for the gramasi variant is still above 7.2 seconds per pcs with a daily target of 9,000 pieces. Proposed improvements to eliminate waste such as equipment re-layout, rejuvenation of rolling equipment, punch, press, engraving can reduce cycle time below the targeted takt time.

Implementation of Lean Manufacturing With A Value Stream Mapping Approach to Improve The Efficiency of The Production Process

<p><strong>This research is based on the fact that many domestic sugar industries operate inefficiently and have low productivity, which is seen when compared to other countries such as Thailand, India and Australia. This study aims to identify and analyze problems along the flow of the white crystal sugar production process that cause waste and then make suggestions for improvements to reduce existing waste to increase cost efficiency in the production process. The national sugar factories generally have a basic problem, namely the low level of factory efficiency, which causes a lot of waste along the flow of the production process. The right concept for solving this problem is the implementation of the Lean manufacturing method, where this method focuses on efforts to reduce waste along the flow of the production process by making continuous improvements. The research begins with a literature study and field study and then conducts observations, analyzes, brainstorms, extracts and collects data from each work unit. The first stage begins with the define which will identify all forms of waste along the production process flow, measure to determine the most critical waste, analyze to identify the factors that cause waste in the production process, improve to carry out improvement plans, and reduce waste that occurs in the production process, and control as an evaluation of improvement results. The efficiency of the production process before the improvement is 78.7%, with improvements expected to increase production efficiency by 87.0% or an increase of 8.3 points.</strong></p><p><strong>Keywords</strong> - <em>Lean Manufacturing, DMAIC, Value Stream Mapping, Waste, Production Efficiency</em></p><p><strong><br /></strong></p>

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

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.

Design of Lean Six Sigma to Reduce Waste in Aerophile Line Production Processes in The Chemical Industry Using DMAIC And VSM Approach

This research was conducted on companies engaged in the chemical industry which are manufacturers of household products such as: air freshener, baby care products, food plastic wrappers, metal polishers, mouse glue, insecticides, lpg cans, car care products, insect repellent, and many more. many other products. The product chosen to be used as research material this time is an aerosol insect repellent product. This research was carried out in the production department of an aerophile line that produces aerosol insect repellents. This study aims to determine the defects and waste that occur in the aerophyll line so that it can improve quality and increase the amount of production in order to meet customer desires. The method used in this research is descriptive which is done by analyzing the production process of one type of product on the aerophile line by observing for 3 months. The results of this study were carried out using the DMAIC (Define, Measure, Analyze, Improve, Control) and VSM (Value Stream Mapping) methods identified 5 types of defects, namely dented cans, missing batch numbers, reject caps, leaks, and low weight. From the calculation results, the average DPU is 0.05, the average DPO is 0.01, the average DPMO is 10278.14, the average production yield is only 68.59% and the level of sigma value is at level 2. Improvements made with Lean Sigma by expanding the capacity of the waterbath and accelerating the process of immersion and raising the temperature in the waterbath, scheduling machine inspections, making checksheets, and work instructions and SOPs. So that we get a decrease in production cycle time from 88 minutes to 83 minutes which has an impact on increasing the production target from 72 pallets/day to 78 pallets/day, and has an impact on the actual number of production from 1,875 pallets/month to 2,028 pallets/month.

Productivity Analysis of Crude Palm Oil (CPO) in PT. Ramajaya Pramukti Using Value Stream Mapping Approach

This study aims to analyze the productivity of CPO processing using Value Stream Mapping (VSM) approach. A case study conducted in PT. Ramajaya Pramukti, Indonesia. The research method used the VSM and Process Activity Mapping (PAM) to determine wastes in the process flow of CPO production. The data was collected in 1 month. The preliminary result of CPO productivity process was average of 73.67%. Based the Future Value Stream Mapping (FVSM) the CPO processing time can be efficient from 1.981 seconds/kg to 1.963 seconds/kg. The productivity processing for value added 1.525 seconds/kg, which non value added of 0.012 and the non necessary value added of 0.383 seconds/kg. The quality of raw materials was the biggest waste contributor. It was caused a longer processing time due to poor quality of raw materials.

An Agile System to Enhance Productivity through a Modified Value Stream Mapping Approach in Industry 4.0: A Novel Approach

Worldwide, industries are emphasizing the development of an agile system to sustain higher productivity, which can be applied to ensure improvements in all production conditions in industry 4.0. In the present scenario, several methods are used for improvements in production, such as value stream mapping, kaizen, just in time, Kanban, and total productive maintenance, etc., The objective of the present research article is to produce an agile system to sustain improvements in productivity through a methodology coupled with value stream mapping in industry 4.0. Value stream mapping is a lean-based method and is used for the maximization of productivity by the elimination of non-value-added activities. The proposed methodology has been validated by productivity enhancements achieved in a case study of the earthmoving machinery manufacturing sector. The study establishes that the proposed methodology would encourage industry personnel during decision-making processes, which would lead to improvements in production in industry 4.0.

Implementation of Lean Manufacturing and Waste Minimization to Overcome Delay in Metering Regulating System Fabrication Process using Value Stream Mapping and VALSAT Method Approach (Case Study: Company YS)

Company YS participates in managing the natural gas network by creating a Metering Regulating System (MRS), which is a tool to measure gas usage and damage to the natural gas network. Based on the data obtained, the MRS delivery process was often not in accordance with the agreed schedule, there was a delay of up to 46%, namely 50 days late from the planned schedule. To overcome these delays, waste reduction is carried out by mapping the overall condition of the company in Value Stream Mapping (VSM) and mapping in detail with the Value Stream Mapping Analysis Tools (VALSAT). In the VSM method, a Current Value Stream Mapping is carried out which then identifies the waste in which the correlation score between the wastes is described in a matrix called the Waste Relationship Matrix then followed by the calculation of the Waste Assessment Questionnaire. Then in the VALSAT method, further waste identification was carried out using seven tools. The most influential percentage of waste that has been obtained is then searched for the root cause using a fishbone diagram and then eliminated and depicted in the Future Value Stream Mapping. The most influential waste in the fabrication process is Waiting and after repairs according to the recommendations, the lead time is obtained from 41,822.60 minutes or 99 working days to 35,055.60 minutes or 83 working days so that the fabrication process can be completed 3 days faster than scheduled.

Analysis of Production Process in Small Business Using Value Stream Mapping Approach

This paper aims to identify waste and analyse production process activities using the Value Stream Mapping (VSM) in a small business as a case study. The waste was identified by a waste relationship matrix and waste assessment questionnaire to determine the percentage of waste that occurs. Furthermore, a detailed selection of waste mapping based on the value stream analysis tool was carried out. Based on the VSM analysis, it was found the value added activities of 59% of the total production time and 41% of other activity times (non value added). In the case study occurred the waste for the operator's work method at the station of printing and cutting station. The VSM was performed to reducing the waste. The result depicted reduction in lead time on the production floor was 1.5 hours. So, the company in the case study can eliminate the waste time in their production process activities

Logistic Service Efficiency Using Value Stream Mapping Approach in the Pharmacy of Class-I Prison Clinic, Malang

A clinic is a healthcare facility providing basic services for individual health, a pharmacy is one of the installations of a clinic. The task of a pharmacy as a unit of a clinic is to organize, coordinate, manage and supervise all pharmacy-related services. The logistics management activities at the Class-I Prison Clinic of Malang include planning, requesting, receiving, storing, distributing, controlling, recording and reporting, as well as monitoring and evaluation. The current research was conducted on the four activities of requesting, receiving, storing and distributing. This study utilized the Value Stream Mapping (VSM) theory as an effort to reduce waste. The study used a quantitative descriptive method with a cross-sectional design. A total of 97 samples including workers involved in logistics management activities and patients seeking treatment were chosen using an accidental sampling method with the Taro Yamene formula. Data were collected through documents, interviews and observations. The results obtained in the distribution process considered all four activities, however, there was still some waste during the process. The calculated value added ratio (VAR) was 61.46%, which means that the clinic implements a lean management.
 Keywords: logistic management, distribution, value stream mapping, drugs

A digital twin-enabled value stream mapping approach for production process reengineering in SMEs

ABSTRACT Nowadays agile and practical methods for lean manufacturing and production process reengineering are in urgent need for Small and Medium Enterprises (SMEs). However, due to the limitations in obtaining accurate performance evaluations of the production line, traditional value stream mapping (VSM) methods are insufficient or unpractical in undertaking production process reengineering tasks. By integrating the internet of things (IoT) technology and Efficiency Validate Analysis (EVA) simulation framework, this paper proposed a digital twin-enabled VSM approach for SMEs. This easy to adopt and accurate method helps manufacturing SMEs in redesigning and reengineering production processes. This study contributes to research on digital twin modeling, by proposing a theoretical framework which combines IoT data-driven production process planning and simulation methods. The novelty of this study also exists in proposing a comprehensive and practical solution for production process reengineering, which integrating the cutting-edge technologies including digital twin and IoT. The feasibility and validity of the proposed approach is proved by applying to a musical instrument factory in China.

Integration of DMAIC, VSM and Valsat to Reduce Waste in Disk Brake Cutting Process Using DMAIC, VSM and Valsat Method Approach (Case Study: Company IM)

The Company IM is a manufacturing company that produces two-wheeled automotive spare parts. One of the products currently being supplied to several two-wheeled customers is the disc brake, rear sprocket, and drive sprocket. The opportunity to increase production output adjusted to high customer demand can be done by reducing waste activities. Therefore, an approach with a lean six sigma approach is needed using the integration method of DMAIC (Define, Measure, Analyze, Improve, and Control), VSM (Value Stream Mapping), and VALSAT. This study aims to reduce production waste and reduce cycle time, affecting increasing production output to balance according to customer needs. Waste identification is explained in the Define stage at DMAIC using a big mapping image in Value Stream Mapping. A more in-depth analysis is carried out using the VALSAT tools at the Analyze stage supported by WRM and WAQ questionnaire data. The Analyze stage was then carried out by analyze using the FMEA method. Control is carried out by standardization and outreach to employees. This study aims to identify and reduce the waste in the production area, especially line-cutting disks. Based on the integration results of lean six sigma with the DMAIC, VSM, and VALSAT methods, the efficiency is obtained from 72% to 96%.

Incorporating Variability in Lean Manufacturing: A Fuzzy Value Stream Mapping Approach

In this paper, value stream mapping (VSM) is integrated with fuzzy set theory to incorporate variability and uncertainty in the lean production system. VSM is one of the primary analytical tools for identifying waste and optimizing a production line. However, the standard VSM fails to consider the variability in manufacturing environments, which is, in fact, one of the root causes of waste. Therefore, this article proposes fuzzy VSM to overcome this weakness. Two alternative forms of fuzzy numbers, triangular fuzzy numbers (TFNs) and normal fuzzy numbers (NFNs), are applied, respectively, to depict time intervals, inventories, and other operating variables in VSM. An industrial case for assessing the validity of the proposed approaches is presented. Both approaches make it possible to incorporate and analyze variability in VSM and can be easily applied to industrial cases, as they only require basic algebraic operations. The obtained results are compared and the choice between TFNs and NFNs is discussed accordingly. A triangular fuzzy VSM tends to overestimate the variability of the process in complex production environment with complicated operational processes. However, it permits a more accurate description of variation in the environment where the optimistic and pessimistic values have very different variations from the core.

Proposition of a method for stochastic analysis of value streams

This article aims at proposing a method to stochastically analyze values streams taking into consideration the effect of critical uncertainty sources on lead time. The proposed method combines value stream mapping (VSM) and Monte Carlo simulation to identify improvement opportunities. To illustrate this approach, we carried out a case study in the special nutrition value stream of a Brazilian public hospital. Results show that the proposed method allows the identification of improvement opportunities that would not be considered in the classical deterministic VSM approach. Further, the integration of the stochastic analysis enables the determination of a more realistic lead time, which supports a more assertive planning and scheduling of the value stream. The proposed method addresses a fundamental gap in traditional VSM without adding much complexity to the analysis procedure, which is a common practical issue in previous works that integrated other stochastic methods into VSM.

Value stream mapping in education: addressing work stress

PurposeTeachers of primary education experience high levels of stress but lack rational coping strategies to reduce their work stress. The paper develops a value stream mapping for education approach and examines its use as a rational coping strategy for teams of teachers and other employees to overcome work-related stressors.Design/methodology/approachThe research process consists of two phases. First, a value stream mapping approach for education is developed, based on literature research. Next, the approach is validated in an action research study to reduce work stress of teachers in educational services. The processes that have been selected by the teachers relate to coping with increased variety, long and uncertain throughput times and unclear specifications.FindingsValue stream mapping for education (VSM4EDU) is a well-structured improvement method based on principles of visualization, participation and process thinking, which helps teachers without background in lean thinking to analyse their processes. Using this method has enabled the team to develop rational coping strategies to reduce their work-related stress.Research limitations/implicationsVSM4EDU has been validated using action research at a single school, which implicates deep insight, but further testing at other schools is welcome. Moreover, VSM4EDU has not been used to develop a future state map.Practical implicationsValue stream mapping is useful in educational settings as long as the educational context is respected in the approach.Social implicationsVSM4EDU empowers teachers and helps to develop co-operation in teams.Originality/valueThe validation of value stream mapping for education is well-documented and original.

Management of Plastic Waste Recycling by Value Stream Mapping

This study explains two recycling process category with plastic pellets and fuel as main products. Fuel can be utilized by vehicles and plastic pellets has economical value. Reduction of waste in plastic waste recycling process was conducted using value stream mapping approach. The research of plastic recycling was done through literature review and direct survey. In first stage, several analyses were made: plastic waste processing category, Value Added Time (VAT) and Non Value Added Time (NVAT), also process time per work station. As the result, current stream mapping was obtained. In the second analysis stage, comparison between two processing category revealed that the highest dissipation came from motion waste, waiting time waste, and movement waste. Big picture mapping was used to improve the quality of waste recycling process based on the procedures that has been established Fore mentioned dissipation can be reduced by adding the number of operator equipped with safety gear in washing and drying.