Value Stream Mapping Tool Research Articles

Reducing Waste in Spare Part Production Process with Lean Manufacturing Approach

In the current era of globalization, competition in the industrial world is increasingly competitive, and then the manufacturing industry must be able to optimize its ability to compete. PT. ABC is a battery production manufacturing company that also produces engine parts for use on the company’s production floor. The inability to meet the punch needs to be used on the battery production floor is one of the problems faced by the company. In the punch production process, some activities are not needed such as operators looking for irregularly located support devices and operators repeatedly measuring the results of object feeding in the manual turning process because there is no standard measurement, which causes the grace period to belong. This study aims to reduce waste in a series of production processes or not valuable adding activities and shortening the total waiting time using the Value Stream Mapping tool. To identify waste, you must first know which activities are of added value and not value added. One method proposed to fix this problem is Lean Manufacturing. The result of using the Lean Manufacturing method is the proposed improvement is to eliminate activities that are less efficient and can reduce production time by 2897 seconds and reduce production activities with 17 events so that the production process is more efficient than before. It can be concluded that the waste that occurs is over processing and movement caused by work methods and machinery.

Melhoria do processo de importação a partir de conceitos do lean

O processo de importação é considerado um processo complexo devido ao alto lead time de suprimento e muita burocracia, ocasionando elevados estoques na importadora. Este artigo apresenta uma proposta de melhoria no processo de suprimentos de itens importados do setor automotivo, a partir da aplicação de conceitos do Lean Office. Para tanto, utilizou-se a ferramenta Mapeamento de Fluxo de Valor (MFV) para entender o fluxo dos itens importados e identificar pontos de desperdício. Assim, foi proposta a utilização de um mix de itens para importação, a partir da demanda do cliente interno e alteração do modal de transporte marítimo para aéreo. Esta proposta possibilitou reduções significativas no estoque e no lead time de entrega, de modo a atender a demanda mais rapidamente, com uma redução de 70% nas atividades que não agregam valor e 73% no tempo total de ciclo do processo de importação. Resultando numa economia anual de R$53.000,00.

The effect of lean six sigma toward maternal emergency lead time in Penembahan Senopati Hospital, Bantul, Yogyakarta

Introduction : Indonesia is one of the countries with high Maternal Mortality Rate that result partially from in management inefficiency, causing in obstruction of flow, underutilized resources, and imbalance between the number of patients with the availability of care facilities and the alternative care strategies. One of the strategies that can be applied to reduce lead time is Lean Six Sigma (LSS). Therefore, the purpose of this study was to evaluate the impact of Lean Six Sigma (LSS) methodology on patient lead time in Maternal Emergency of district government hospital.Methods: Researcher and the participants were involved in planning, gathering data, analyzing, and choosing the best solutions. The participants were trained on LSS methods, its implementation tools and procedures. Evaluations were conducted using lead time observation before and after implementation, and midwives were interviewed about their perceptions. The analysis was based on Value Stream Mapping tools. Results: Patients’ lead time from being admitted in emergency unit definitive diagnosis was decreased by 26.04 minutes or 16.4% in Caesarean Section (CS) and 15.25 minutes or 21.7% in other maternal high risk. For emergency CS, the improvement was 33.06 minutes or 26% from decision until incision. The benefit of LSS implementation was primarily in accelerating service processes and improving communication and team work. Conclusion: This study showed that the implementation of LSS had great potential benefit in a maternal emergency unit. Participation of the midwives is crucial for successful implementation of LSS to reduce patients lead time.

Developing a lean model to reduce the design process cost of gas insulated switchgear foundation using value stream mapping – a case study

Construction industry across the world has been facing immense challenges in improving its productivity and efficiency. In the path of continuous improvement, the companies are forced to impart new technologies and methods into their work culture. But still there is a fine line between what they have achieved and what they wanted to achieve. Lean Construction is an ideology designed to fill this fine line. The aim of this paper is to discuss the application of Lean techniques in construction management. A case study where the Lean concept is applied using Value Stream Mapping tool to reduce the cost of the design process of foundation for Gas Insulated Switchgear by improving the process productivity has been discussed. The current state of the activities in the design process was mapped first which was followed by preparing the future state map of the activities after eliminating the non-value adding tasks. The results exhibited a promising increase in productivity of about 30% after the application of Lean tool.

Methodology for integrated management system improvement: combining costs deployment and value stream mapping

Integrated Management System – Quality, Environment, Safety (IMS-QES) combines all related components of a business into one system for easier management and operations Quality (QMS/ISO 9001), Environmental (EMS/ISO 14001), and Health & Safety (OHSAS 18001). IMS-QES has been generally used to increase operational performance in manufacturing systems. However, the economic impact of standard approach of IMS-QES remains difficult due to the lack of alignment between IMS-QES objectives and strategic management of the company (policy of IMS-QES) and also the inadequacy between the improvement processes and the cost of losses. Therefore, the main objective of this work is to overcome this limitation. The Framework proposed approach called IM-VCF integrates concepts from IMS-QES, Value Stream Mapping and Cost Deployment tool. It is structured in ten steps. It allows a company to assure proper alignment between IMS-QES policy and business operations and identify the categories of losses. IM-VCF allows analysing critical issues and estimating the potential savings, in terms of cost. A case study taken from the application of the IM-VSF within certified QSE chemical fertiliser port is presented.

Applying value stream mapping tools and kanban system for waste identification and reduction (case study: a basic chemical company)

This paper describes how to apply both of value stream mapping tools and kanban system for identifying and reducing wastes that happened on shop-floor. This research was conducted at a basic chemical company which produces the thinner. This study aims to reduce even to eliminate the types of waste that occur on the production line of jerrycan product type. The plot of VSM is used to picture the entire of value stream. The value stream mapping tools are used to analyze the certain waste after it has been figured out by using waste assessment model. Hence in this study two selected tools were applied and discussed further, i.e. process activity mapping, and supply chain response matrix. The Current-VSM shown that value-added time of 472.33 s compared with total lead time of 132,568.76 s, consequently obtained process cycle efficiency (PCE) approximately 0.36%. Kanban system will be implemented to eliminate waste of unnecessary inventory throughout the value stream. At last, the result of improvements shown that value of PCE probably will increase by 67.25%, non-value activity will reduce 6.74%, as well as order fulfillment time of the whole process will be 13 days with 3.59 days of physical stock.

Production process analysis using value stream mapping at East Java sugarcane industry

The purpose of this research is to identify the type of waste and to propose improvements for waste minimization on the processing process at the sugarcane industry. This research uses Value Stream Mapping and Value Stream Analysis Tools (VALSAT) method. The results showed that the highest waste in the process production consisted of waiting time and inappropriate processing. Recommendations for improvements that given include reduction of time at several stages of the process, and perform periodic maintenance of the machine. Process Activity Mapping analysis shows reduced lead time from 1212.07 minutes to 1176.23 minutes.

Evaluation of value stream mapping (VSM) applicability to the oil and gas chain processes

PurposeLean approach has overcome the boundaries of the automotive and manufacturing industry and has achieved many different sectors of the economy, including services. In this context, this paper aims to investigate the applicability of value stream mapping (VSM) tool in processes of the oil and gas chain. Also, this paper investigates if there is a specific framework currently being used by organizations belonging to this chain to map the value stream of its processes.Design/methodology/approachA detailed systematic review of the literature is done by using a set of relevant keywords based on peer-reviewed journal articles and conference papers available in the Scopus database, analyzing data from 2012 to 2017. Content analysis methodology involving a four-step process (identification, screening, eligibility and inclusion) suggested by Moher et al. (2009) was adopted for this study.FindingsThe number of studies in literature on VSM applicability to the oil and gas chain processes is low when compared to studies regarding the application of lean tools and methods in general in this area. Also, there is no specific framework that has been used by the oil and gas chain companies to carry out the VSM, which is a research gap that can be further explored.Research limitations/implicationsSample size for this research consists of 42 studies, thereby limiting the generalizability of the research studies. However, the analysis presented in this paper was based only on Scopus database, which is a remarkable and broad base, which provided robustness to the data found.Practical implicationsPracticing managers of oil and gas chain who are planning to transform their processes can use the VSM for it. Researchers can explore the research gap found in this study and develop a specific framework to implement VSM in the oil and gas chain processes.Originality/valueThis is the first paper to evaluate the VSM tool applicability to the oil and gas chain processes based on an systematic literature review and understand if this is possible and if there is a specific framework to carry out this task.

REKAYASA PERBAIKAN PROSES PRODUKSI BONEKA DENGAN INTEGRASI METODE LINE BALANCING DAN VALUE STREAM MAPPING

Pradamas Toys is a small and medium industrial company in producing dolls with yelvo fabric base material. The purpose of this study is to know the waste in the puppet production process at Pradamas Toys and to propose improvement of production process to minimize waste and improve production process efficiency in Pradamas Toys. This research uses lean approach with value stream mapping (VSM) tools, at the beginning of the research done depiction of current state mapping on Pradamas Toys, after that do problem analysis using line balancing to leveling cycle time, fishbone diagram used to know factors causing production problem puppets and waste identification in each production process, then analyzed 5 Why and 5W1H to give suggestions for improvement of production process at Pradamar Toys. At current state mapping the production process time is 18.6032 minutes with a lead time of 9 days. After doing the calculation and equalization cycle time by using line balancing, then got the proposed future state mapping for doll production with process time of 14,7300 minutes and lead time of 5 days.

Kaizen Selection for Continuous Improvement through VSM-Fuzzy-TOPSIS in Small-Scale Enterprises: An Indian Case Study

In the era of cut throat competitive market, Indian industries are under tremendous pressure to continuously reduce the cost and improve product quality. The main objective of this research paper is to provide a road map for investigating the opportunities to reduce cost and improve productivity and quality in the existing production system through the application of Lean-Kaizen concept using value stream mapping (VSM) tool at shop floor of an Indian Small-Scale Enterprise (SSE). On the basis of collected data from the selected industry, a current state map was made. After analysis, the current state map was modified to develop a future state map. By comparing current and future state map, the gap areas were identified and takt time (TT) was calculated considering actual market demand. To overcome the gap between current state map and future state map and to synchronize cycle time of each station with talk time, Kaizen event (KE) was proposed. Fuzzy technology for order preference by similarity to ideal solution (TOPSIS) was applied to prioritize and select the appropriate KE for optimized performance level. After analysis of data obtained after application of the Lean-Kaizen concept, the final improvements in terms of improved productivity (57.15%) and reduced lead time (69.47%), reduced cost (65.61%), and station cycle time (75.25%) were recorded. Through the case study drawn from realistic situations of the industry, the authors highlight that implementation of Lean-Kaizen using VSM and fuzzy TOPSIS provides improvement opportunities across the organization. The findings can inspire the SSEs to adopt the Lean-Kaizen concept for optimizing continuous improvement opportunities in their production industry. This study offers the researchers and practitioners a good example for understanding, selecting, and performing KE program. They can even attain more improvement in various areas by establishing or improving these KE programs.

A PDCA-based approach to Environmental Value Stream Mapping (E-VSM)

Abstract Research into the application of Value Stream Mapping (VSM) as a tool to enhance the environmental sustainability performance of operations has been confined to a handful of studies only. Research on this green lean research stream is therefore limited, especially when compared to the vast amount of scholarly research focused on the ‘traditional’ VSM tool. To complement and support the narrow body of knowledge on the application of VSM as tools to improve environmental performance and enhance the effectiveness of its application, this paper proposes an approach, based on the Deming's Plan-Do-Check-Act (PDCA) improvement cycle, to systematically implement and conduct Environmental-VSM (E-VSM) studies. The implementation of the proposed method is reported through an action research-based case study conducted in a helical rolling process of one of the mining consumables business units of an international diversified mining and materials multinational company. The results of the case study indicate that the proposed PDCA-based approach to E-VSM can be an effective alternative to improve the green performance of operations. Besides the proposal of this approach, its testing, and expanding the body of knowledge in the green lean field, the paper also contributes by providing a guiding reference for operations managers who may want to make the operations of their organisations more sustainable and environmentally friendly. Finally, this paper also intends to contribute by inspiring researchers and practitioners to broaden the study of the under-researched field which explores the application of VSM for environmental sustainability enhancement.

Lean Manufacturing: Waste Reduction Using Value Stream Mapping

Cristal Sri Sujarwati is a small medium enterprise (SME) that produce keripik salak in Sleman, Yogyakarta. To survive and win industrial competition, Cristal Sri Sujarwati was required to improve its performance. But in reality there was a lot of waste in order fulfillment processes marked by ineffective and inefficient work. In this research, lean manufacturing aims to identify and eliminate waste so that the company could improve its performance in winning the industry competition. Lean manufacturing is a systematic approach used to identify and eliminate waste. This lean concept could improve responsiveness through waste reduction, continuous improvement and cost reduction. In order to identify and eliminating waste, a value stream mapping tools, waste weighting questionnaire, value stream analysis tools, and fishbone diagram are used. From the results of research, the dominant waste in the production process was waste defects, waiting, and unnecessary inventory. To eliminate waste, process activity mapping (PAM), the one of detailed mapping tools in VALSAT are used. From the results of the improvement recommendations analysis, lead time decreased by 80 minutes. From the analysis using PAM, there was a reduction of NVA activity from 3.10% to 1.01%.

Cost Based Value Stream Mapping as a Sustainable Construction Tool for Underground Pipeline Construction Projects

This paper deals with application of Value Stream Mapping (VSM) as a sustainable construction tool on a real construction project of installation of underground pipelines. VSM was adapted to reduce the high percentage of non-value-added activities and time wastes during each construction stage and the paper searched for an effective way to consider the cost for studied construction of underground pipeline. This paper is unique in its way that it adopts cost implementation of VSM to improve the productivity in underground pipeline projects. The data was observed and collected from site during construction, indicating the cycle time, value added and non-value added of each construction stage. The current state was built based on these details. This was an eye-opening exercise and a process management tool as a trigger for improvement. After the current state assessment, a future state is attempted by Value Stream Mapping tool balancing the resources using a Line of Balance (LOB) technique. Moreover, a sustainable cost estimation model was developed during current state and future state to calculate the cost of underground pipeline construction. The result shows a cost reduction of 20.8% between current and future states. This reflects the importance of the cost based Value Stream Mapping in construction as a sustainable measurement tool. This new tool could be utilized in construction industry to add the sustainability and effective cost management.

Os PRIMEIROS PASSOS EM BUSCA DA TRANSFORMAÇÃO ENXUTA:

A busca da excelência operacional, através da eliminação das perdas e desperdícios com a utilização dos conceitos de manufatura enxuta, já é amplamente difundida nas grandes empresas manufatureiras, mas nas pequenas empresas estes conceitos ainda não são práticas usuais. Este artigo tem como objetivo apresentar um estudo de caso do início da transformação enxuta em uma fábrica de painéis isotérmicos na região da Grande São Paulo através da implantação da ferramenta de Mapeamento do Fluxo de Valor (MFV). A família de produtos de painéis de 100 milímetros de espessura foi selecionada e em seguida foi realizado o MFV do estado atual e futuro. Os resultados obtidos foram expressivos com a redução do lead time em mais de 18% e no tempo de agregação de valor no produto em mais de 76%, outro resultado significativo foi a redução em mais de 66% no WIP. Como em toda empresa com mudanças culturais muito profundas o grande desafio é manter e expandir os conceitos de manufatura enxuta.

WASTE ELIMINATION USING VALUE STREAM MAPPING AND VALSAT

Fierce competition encourages companies to make continuous improvements to achieve better working efficiency. One method to improve the working efficiency is using the concept of lean manufacturing. The efficiency of the existing work in PT. Rimba Kencana is still not good because there are many processes that are not uniform and because of that, production lead time is increased. By using value stream mapping and value stream analysis tools (VALSAT), the production processes in the company are mapped into the current state mapping and future state mapping. In the current state mapping, the total value of production lead time is 59.49 days and the value of process cycle efficiency (PCE) is 0.013%. After doing improvement on welding department, the total value of production lead time decreased to 48.22 days and the value of process cycle efficiency becomes 0.016%. Keywords: Efficiency, Value Stream Mapping, Value Stream Analysis Tools

Gap Analysis of Value Stream Mapping Tool Implementation in Manufacturing Operation using Fuzzy Topsis

In today’s world, technology plays a vital role demanding productivity improvements, downtime reduction in manufacturing operations industry. Depending upon the strategy and lean methodology organizations follow and apply VSM and JIT in their respective fields. The present research work discusses the methodology to determine the gap analysis of VSM tool implementation in manufacturing operation in a different set of companies using fuzzy topsis. The algorithm and methodology determines the prioritization of various factors that can and will play an important role in implementation of VSM Tool across different organizations. The methodology will determine the ranking of organization based on the closeness coefficient. ysis.

Integrating sustainability indicators and Lean Manufacturing to assess manufacturing processes: Application case studies in Brazilian industry

Operation management models have been developed according to changes in society's demands, such as better working conditions, clean production, recyclable and reusable products, and improving social conditions. Thus, new challenges in developing sustainable management models, particularly for manufacturing processes, have emerged. Lean Manufacturing and Value Stream Mapping (VSM) have been widely used to develop manufacturing processes without wastes in the production flow. However, current indicators of the VSM tool have not identified the economic, social and environmental factors. This work aims to propose a conceptual method to integrate a new group of sustainability indicators into the VSM tool to assess manufacturing processes. The development of sustainability indicators was performed through analysis of the assessment models of sustainability and sustainability indicators in the period of 2009–2014. The method was applied in three case studies, and the results demonstrated that the proposed method identified different levels of sustainability of manufacturing processes and thus enabled the development of improved scenarios. In this sense, the results contributed to the literature with the proposition of new sustainability indicators related to the manufacturing process. The case studies enabled evaluation of the interaction of a new group of sustainability indicators in different manufacturing processes.

METHODOLOGY TO PRODUCE A WATER AND ENERGY STREAM MAP (WESM) IN THE SOUTH AFRICAN MANUFACTURING INDUSTRY

The increasing demand for water and energy in South Africa, and the capacity constraints and restrictions of both resources, have led to a rapid increase in their cost. The manufacturing industry remains South Africa’s third-largest consumer of water and second- largest consumer of national energy. The improvement of water and energy efficiency is becoming an increasingly important theme for both organisational success and national economic sustainability. This paper presents the ‘lean based water and energy stream mapping framework’ developed for the manufacturing industry, with the specific objective of decreasing its water and energy intensity. As with the traditional value stream mapping tool, the water and energy stream mapping focuses on eliminating water- and energy-specific wastes within a process. Water and energy waste categories that will be used in conjunction with the framework will also be discussed. The key objective of this paper is to detail the process of creating the water and energy stream mapping, and the statistical forecasting methodology used to develop the baseline water and energy demand data. The outcome of the implementation of the framework is the future state water and energy stream mapping, which is effectively a blueprint for increased water and energy efficiency within a studied process.

ANÁLISE DA CADEIA DE SUPRIMENTOS DE UMA EMPRESA QUÍMICA UTILIZANDO MAPA DE FLUXO DE VALOR

The focus of business management has changed throughout the years. Logistics activities have become more important and represent one of the main ways of differentiation regarding competition. Chemical companies responsible for goods imports in Brazil need to differentiate their service level through performance improvements in the supply chain processes in which they operate. The objective of this study is to analyze the supply chain of a large size chemical company, and verify the possibility of improving its logistics service level. The chain analysis was done by means of Value Stream Mapping (VSM) tool, which enabled diagnosis of the initial state of its processes (as is), identify wastes and propose changes by modeling a future state (to be). The main results of the mapping were the improvements in process waiting times, with a reduction of the total lead time of 23% and a 12% increase in the customer value-added time.

An Application of Value Stream Mapping in Ceramic Tile Industry: A Case Study

The purpose of this paper is to increase the productivity of a ceramic tile manufacturing process using lean manufacturing technique. The current system of the ceramic tile manufacturing process has been mapped using Value Stream Mapping (VSM) tool, which is a lean manufacturing tool and the wastages in the current system are identified. Afterwards, future state has been created by using VSM tool, which has enhanced process ration by decreasing maximum possible waste in the manufacturing process. The case study demonstrates how the VSM tool has been used to identify and reduce waste in the manufacturing process by 26%, unnecessary inventory by 8.33% and working time of the color-mixing department by 21.57%. This flexibility enhancement causes 2.67% shorter lead time, 2.70% higher value-added ratio and frequent product delivery leading to more profits.