Development of sustainable value stream mapping (SVSM) for unit part manufacturing

2019 ◽  
Vol 11 (3) ◽  
pp. 493-514 ◽  
Author(s):  
Aatish Kumar Mishra ◽  
Ayush Sharma ◽  
Moraldeepsingh Sachdeo ◽  
Jayakrishna K.
Keyword(s):  
Manufacturing Industry ◽  
Main Tool ◽  
Organizational Level ◽  
Value Stream Mapping ◽  
Simulation Approach ◽  
Content Type ◽  
Study Approach ◽  
Value Stream ◽  
Sustainable Value

Purpose The main purpose of this paper is to analyze the current state of a bonnet-manufacturing industry and to optimize the process by designing a future state map using simulation approach. Design/methodology/approach The case study approach has been proposed to highlight the applicability of value stream mapping (VSM) in an Indian bonnet manufacturing organization. The methodology used relies on formulation of VSM being the main tool used to identify the opportunities for classifying and eliminating bottlenecks with the help of various lean techniques. A contrast of present and past scenarios is highlighted to underscore the importance of using VSM with ARENA simulation. Findings Application of the proposed simulation approach has helped the organization reduce the cycle time significantly by 30 per cent over the entire production time. The average number of work-in-progress pieces has also decreased by about ten. In addition, enhancements have been seen with respect to ecological parameters, e.g. carbon footprint has been reduced to 83.7 percent across the process. Research limitations/implications The proposed approach of using a simulation-based VSM helps in reducing the time involved in traditional VSM method. This approach is also easy to implement at any organizational level. Practical implications It is believed that this paper will aid not just industrialists but also academic professionals to appreciate the role of simulation using ARENA in helping them understand how to attack the various problems faced by industries. The results of the study indicate that by applying this methodology, there will be a reduction not only in cost but also in environmental impacts. Originality/value The paper incorporates a real case study, which shows application of VSM for implementing lean principles in a bonnet-manufacturing industry. Break-even analysis presented fills the gap which previous literatures have been missing.

Application of lean in construction using value stream mapping

2019 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Prasanna Venkatesan Ramani ◽  
Laxmana Kumara Lingan KSD
Keyword(s):  
Construction Projects ◽  
Manufacturing Industry ◽  
Value Stream Mapping ◽  
Content Type ◽  
Project Duration ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Increase In Productivity

Purpose Lean construction is a technique that aims at reducing waste in construction and maximizing productivity. The purpose of this paper is to discuss the effectiveness of Lean technique in managing construction projects. Design/methodology/approach A case study of structural steel erection project was chosen where the value stream mapping lean tool is applied and the possible improvement in productivity was observed. The current state of the activities in the erection process was mapped first which was followed by preparing the Future State Map of the activities after eliminating the non-value adding tasks. Findings The modifications from Future State Map were carried out at the project and the results exhibited a substantial increase in productivity by reducing the project duration by 13 days which is about 30 per cent savings from the expected completion time after the implementation of Lean technique. Originality/value Traditionally lean concept has been widely used in process-oriented manufacturing industry whereas it is relatively new to the project-oriented construction industry. This current research has focused on applying lean tool to a real time construction project at the site level and measuring its outcome practically. The results of this study are real and affirm the effectiveness of applying lean concept to construction projects. It will be major paradigm shift in terms of managing construction projects.

Mitigating the effects of COVID-19: an exploratory case study of the countermeasures taken by the manufacturing industry

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Atif Saleem Butt
Keyword(s):  
United Arab Emirates ◽  
Manufacturing Industry ◽  
Manufacturing Firms ◽  
Structured Interviews ◽  
Cross Sectional ◽  
Content Type ◽  
Study Approach ◽  
Process Manufacturing ◽  
The Impact

Purpose The purpose of this study is to understand how manufacturers (both discrete and process) are managing disruptions amid the COVID-19 pandemic outbreak, using UAE as an empirical context. Design/methodology/approach This research uses a multiple case study approach and undertakes 36 semi-structured interviews with senior management of four discrete and four process manufacturing firms that outsource products/components from overseas and domestic suppliers. Findings Results reveal that manufacturing firms are using six distinct actions to mitigate the effects of the COVID-19 pandemic. For instance, they are relying on the automation process, transferring new and updated knowledge to the current and new suppliers, managing workforce diversity, understanding the impact of demand’s disruption, managing the ecosystem and finally using digital technologies to mitigate the impact of the COVID-19 pandemic. Research limitations/implications This study has some limitations. Firstly, the results of this study cannot be generalized to a broader population as it attempts to build an initial theory in manufacturing supply chains within the context of a pandemic outbreak. Second, the study uses a cross-sectional approach to explore the actions used by manufacturing firms to mitigate the effects of the COVID-19 pandemic. Practical implications Manufacturing firms can replicate the actions proposed in this study to lessen the effect of the COVID-19 pandemic and emerge stronger in the post-COVID-era. Originality/value This study contributes to the manufacturing supply chain literature within the context of pandemic outbreaks by exploring the steps taken by manufacturing firms to minimize the effects of the COVID-19 pandemic. Particularly, it explores such steps by considering both the discrete and process manufacturing industries within the United Arab Emirates.

Application of Lean Six Sigma framework for improving manufacturing efficiency: a case study in Indian context

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Astha Sharma ◽  
Neeraj Bhanot ◽  
Ajay Gupta ◽  
Rajeev Trehan
Keyword(s):  
Simulation Model ◽  
Six Sigma ◽  
Production Line ◽  
Manufacturing Industry ◽  
Lean Six Sigma ◽  
Expected Improvement ◽  
Batch Size ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream

PurposeThis study aims to utilize DMAIC methodology along with value stream mapping and other Lean Six Sigma tools in a major automobile light manufacturing industry to reduce defect rates and increase production capacity in their manufacturing line. The study also proposes a modified framework based on lean principles and FlexSim to identify and reduce waste in the selected industry.Design/methodology/approachA Lean Six Sigma modified framework has been deployed with DMAIC to reduce the defect rate and increase the production rate. Various tools like value stream mapping, brainstorming, Pareto charts, 5S, kanban, etc. have been used at different phases of DMAIC targeting wastes and inventory in the production line. Also, a simulation model has been utilized for the automobile light manufacturing industry to improve the machine utilization time with varying batch sizes.FindingsThe results of the study indicated a 53% reduction in defect rates. Thus, there would be an expected improvement in sigma value from 3.78 to 3.89 and a reduction in defects per million opportunities (DPMO) from 11,244 to 8,493. Additionally, simulation model using FlexSim was developed, and the optimum ordering batch size of raw material was obtained. It was also analyzed that idle time for various stations could be reduced by up to 30%.Practical implicationsThe utilized framework helps identify defects for managers to increase production efficiency. The workers, operators and supervisors on the production line also need to be trained regularly for identifying the areas of improvement.Originality/valueThe modified Lean Six Sigma framework used in this study includes FlexSim simulation to make the framework robust, which has not been used with LSS tools in the literature studied. Also, the LSS finds very less application in the manufacturing domain, considering which this study tends to add value in existing literature taking a case of an automobile light manufacturing industry.

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

2018 ◽  
Vol 11 (2) ◽  
pp. 309-330 ◽  
Author(s):  
Cicero Vasconcelos Ferreira Lobo ◽  
Robisom Damasceno Calado ◽  
Roberta Dalvo Pereira da Conceição
Keyword(s):  
Manufacturing Industry ◽  
Oil And Gas ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Chain Processes ◽  
Analysis Methodology ◽  
Research Gap ◽  
Scopus Database ◽  
Conference Papers

Purpose Lean 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/approach A 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. Findings The 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/implications Sample 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 implications Practicing 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/value This 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.

Impacts of Kaizen in a small-scale industry of India: a case study

2014 ◽  
Vol 5 (1) ◽  
pp. 22-44 ◽  
Author(s):  
Amit Kumar Arya ◽  
Sanjiv Kumar Jain
Keyword(s):  
Poor Quality ◽  
Value Stream Mapping ◽  
Small Scale ◽  
Content Type ◽  
Value Stream ◽  
Small Scale Industry ◽  
Production Techniques ◽  
Small Industries ◽  
Small Scale Industries

Purpose – A large number of small-scale industries have shown their existence in India, tough competition among them made the survival of small industries difficult. All facing problems like reduced production and poor quality. The case study presented in the paper deals with Kaizen implementation in a machine vice manufacturer company. Kaizen has tremendous impacts on the production techniques and lead times. Case study represented is to motivate practitioners for implementing Kaizen in small-scale industries of India. The paper aims to discuss these issues. Design/methodology/approach – The methodology applied to implement the Kaizen in Indian small-scale industry. Fishbone diagrams have been used to represent cause and effects. The result has been shown as savings in terms of money and time. Findings – Processing time has been reduced by 44.4 percent and an amount of Rs. 64,000 has been saved by recovering a total of 80 square feet working area. Improvements in the form of work flow have been achieved. Research limitations/implications – Value stream mapping can be integrated with Kaizen for more reduction in the product lead time. Practical implications – The paper will be worthily for practitioners and consultants for understanding Kaizen implementation in small-scale industry of India. Originality/value – The paper yields lots of values for practitioners to understand the impacts and significance of the Kaizen in small-scale industries of India. Also it bridges the gap between theory and practical of Kaizen implementation in small-scale industry of India.

Implementation of Lean Tools in an Automotive Industry for Productivity Enhancement - A Case Study

2017 ◽  
Vol 29 ◽  
pp. 175-185 ◽  
Author(s):  
S. Nallusamy ◽  
M.A. Adil Ahamed
Keyword(s):  
Automotive Industry ◽  
Manufacturing Industry ◽  
Value Added ◽  
Value Stream Mapping ◽  
Lean Principles ◽  
Value Stream ◽  
Whole Process ◽  
Lean Tools ◽  
Cycle Efficiency

Value stream mapping has the reputation of uncovering waste in manufacturing, production and business process. This helps in identifying and removing or streaming value added steps and eliminating non value added steps. In this study the process was analyzed to find an opportunity to drastically reduce the number of actions and to simplify the same. By reducing waste the proportion of value adding time increases in the whole process and the process throughput speed could also be increased. This makes the redesigned process more effective and more efficient. The reengineered process was flow charted in its future state with process steps and information flows re-engineering, simplified and economized. The current layout was analysed to identify and eliminate the non value added activities through lean tools like 5S, VSM and line balancing in a manufacturing industry. From the observed results, it was concluded that the non value added time could be reduced by about 13% while the process cycle efficiency could be increased by about 10%. Virtual simulation was conducted to verify and validate the existing situation as well as to propose the results and the effectiveness of lean principles in a systematic manner with the help of ARENA.

Empirical assessment of the future adequacy of value stream mapping in manufacturing industries

2018 ◽  
Vol 29 (5) ◽  
pp. 886-906 ◽  
Author(s):  
Andreas Lugert ◽  
Aglaya Batz ◽  
Herwig Winkler
Keyword(s):  
Industry 4.0 ◽  
Manufacturing Industry ◽  
Point Of View ◽  
Current Status ◽  
Value Stream Mapping ◽  
Content Type ◽  
Empirical Survey ◽  
Value Stream ◽  
Research Activities ◽  
The Impact

Purpose Value stream mapping (VSM) is very common in the manufacturing industry to enhance transparency and support improvements within the production process. The purpose of this paper is to evaluate the current status of the method from the user’s point of view and addresses its future sustainability in the context of the ongoing digitalization. Design/methodology/approach An empirical survey with 170 participants from different branches was conducted. The web-based questionnaire covers the topics Lean Management, respectively, VSM, Industry 4.0, the integration of both approaches as well as a possible need for action to modify the VSM. Results are analyzed in a quantitative way. Findings Benefits and shortcomings of VSM are already confirmed by previous publications. The serious challenge is the lack of flexibility of the method. In general users appreciate a combination of Lean methods and solutions of Industry 4.0. Moreover 92 percent of the participating experts request further development of the VSM using digitalization to compensate weaknesses. Research limitations/implications The findings are based only on Lean expert’s opinion. Over 95 percent of the participants are from Europe however most of them are from Germany. Although the results are adequate an international expansion of the survey would be advisable in order to distinguish local differences and similarities. In future work researchers need to further develop VSM to overcome the identified gaps. Practical implications Results of the study indicate the viewpoint of experts within different branches. This enables users to undertake a self-assessment regarding their own VSM-estimation. Originality/value This paper provides a current evaluation of the VSM from an exploratory perspective. The impact of global trends and new opportunities facilitated by digitalization are considered. Shortcomings and fields of actions become clear. Based on that necessity further research activities can be designed.

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