Application of value stream mapping (VSM) in low-level technology organizations: a case study

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Hiluf Reda ◽  
Akshay Dvivedi
Keyword(s):  
Cycle Time ◽  
Promising Result ◽  
Product Family ◽  
Value Stream Mapping ◽  
Industrial Case Study ◽  
Content Type ◽  
Low Level ◽  
Value Stream ◽  
Time And Motion

PurposeThis research aims to improve the performance and productivity of low-level technology organizations using lean tools – value stream mapping (VSM). In order to investigate the application of VSM in low-level technology organizations, this study takes footwear manufacturing organizations as a case study.Design/methodology/approachIdentifying a suitable organization was the first step for conducting the case study, followed by product family identification. Time and motion studies are used to determine the cycle time and identify the value-adding and non-value-adding activities, respectively. After making necessary observations and calculations, the current state map was developed. Different improvement proposals were identified, and the future state map was constructed.FindingsAs a result, 56.3% cycle time reduction and 69.7% reduction in lead time were obtained, confirming its application in low-level technology organizations to improve their performance and productivity. This promising result indicates that a significant improvement can be achieved if VSM is applied in low-level organizations other than footwear industries, such as the clothing and furniture industries. Speed is investigated to be one of the parameters in motion study.Research limitations/implicationsThis study focuses on low-level technology organizations, specifically leather shoe manufacturing industries. But experiences gained from implementing this study are realistic and applicable in similar organizations.Practical implicationsPerformance and productivity improvement are critical issues to be addressed in low-level technology organizations, especially in the leather footwear manufacturing sector. This can be achieved through VSM by identifying and removing the wastes. VSM can be applied to low-level organizations as well. VSM is a powerful tool that helps managers and practitioners in identifying wastes and opportunities for improvement.Originality/valueThe paper addresses applicability of VSM in the production process of low-level technology organizations with an original industrial case study in Ethiopia.

An application of value stream mapping in auto-ancillary industry: a case study

2019 ◽  
Vol 32 (1) ◽  
pp. 162-182 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Srinivas Kota ◽  
Kuldip Singh Sangwan
Keyword(s):  
Product Family ◽  
Value Stream Mapping ◽  
Inventory Level ◽  
Specific Product ◽  
Content Type ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Auto Component

Purpose Lean manufacturing (LM) plays a major role in eliminating wastes (activities/resources) in a manufacturing organization. Value stream mapping (VSM) is one of the critical tools in LM which will help in identifying wastes in materials and information flow in a specific product family. The purpose of this paper is to illustrate the significance of VSM in the auto-ancillary industry in enhancing the productivity and the quality. Design/methodology/approach A case study approach is followed to demonstrate the significance of VSM in identifying various wastes in the auto-ancillary industry. The study has been performed by implementing seven critical steps. A product family is identified based on the customer demand and a cross functional team with specialized experts was formed. The overall processes with sequence are mapped using process flowchart. A cross functional team has been formed to develop the current state of VSM and perform a critical analysis to identify shortcomings. An investigation was performed to overcome the existing shortcomings by identifying opportunities. The relevant kaizens to improve the current state have been proposed. The cross functional team of experts have performed a feasibility study on implementation of proposed kaizens. Finally, a future state of VSM after implementation of feasible kaizens has been reported. Findings The results show that future state of VSM brings out the positive impact with respect to process ratio, TAKT time, process inventory level, total lead time and bottleneck time. The proposed improvement also helped to achieve higher customer satisfaction in terms of increased quality, reduced cost and on time delivery. Research limitations/implications Present study is focussed on a single product family cell in one of the auto-component organization. Originality/value Helps practitioners in the auto-component industry to implement the VSM effectively in their organization.

Adaptation of the value stream mapping approach to the design of lean engineer-to-order production systems

2014 ◽  
Vol 25 (3) ◽  
pp. 334-350 ◽  
Author(s):  
D.T. Matt
Keyword(s):  
Production Systems ◽  
Relevant Literature ◽  
Value Stream Mapping ◽  
Special Focus ◽  
Plant Design ◽  
Industrial Case Study ◽  
Content Type ◽  
Value Stream ◽  
Engineer To Order

Purpose – The purpose of this research is to examine relevant parts of the case of an Italian steel construction company's green field plant design process to identify best practice guidelines for the adaptation and use of value stream mapping (VSM) in the design of lean engineer-to-order (ETO) production systems. Design/methodology/approach – The paper reviews the most relevant literature in the field of VSM and discusses its limitations regarding the application in an ETO environment. Based on the analysis of an industrial case, the original VSM methodology is adapted with a special focus on ETO. Information was collected through multiple site visits and semi-structured interviews with the company's key staff of the project, as well as examination of relevant company documentations. Findings – A set of guidelines was developed on the basis of an industrial case research. In this context, major attention was given to two aspects: the introduction of synchronization points in front of merge-activities in the value stream, and the splitting of customer orders into suitable production orders and equal time increments of work. Research limitations/implications – The findings of this research are limited due to the focused nature of a case study-based research. However, the obtained results encourage assuming its transferability to similar problems. Originality/value – This paper provides an original industrial case study with valuable insights for the adaptation of the VSM methodology to batch-of-one ETO environment.

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.

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.

Lean manufacturing implementation using value stream mapping as a tool

2014 ◽  
Vol 5 (1) ◽  
pp. 89-116 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Aditya Sharma
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Process Time ◽  
Inventory Level ◽  
Specific Product ◽  
Content Type ◽  
Value Stream ◽  
Work In Process ◽  
Current State

Purpose – Value stream mapping (VSM) is a lean manufacturing (LM) tool used for analyzing material and information flow on a specific product family. The purpose of this article is to address the importance of VSM in LM environment in an Indian auto components industry. Design/methodology/approach – The case study approach has been used to show the applicability and importance of VSM in an Indian auto components company, in which the current state of manufacturing is mapped with the help of VSM symbols. According to the current state mapping, the study conducted analysis and identifies the area of improvement needed in terms of work in process, lead time and cycle time. The study further implemented kaizen on the current state map and developed future state map while including these kaizens. Findings – The study clearly shows that the VSM brings out the positive impact on process ratio, TAKT time, process inventory level, line speed, total lead and process time and reduced man power. It is helping the company in satisfying their customers with respect to quality, cost and delivery. Research limitations/implications – The main limitation of the study is the confined focus on a single industry. The case should be extended to other industries in order to support the findings and for the purpose of the wider generalization. Practical implications – The results obtained from the study will help other industries and sectors to implement VSM in LM environment. Originality/value – The article deals with a real case study, which shows application of VSM for implementing lean principles.

The practical relationship between continuous flow and lean construction in SMEs

2019 ◽  
Vol 32 (2) ◽  
pp. 362-380
Author(s):  
Wallace Avelar ◽  
Marcelo Meiriño ◽  
Guilherme Luiz Tortorella
Keyword(s):  
Workforce Planning ◽  
Value Added ◽  
Lean Construction ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Time And Motion ◽  
Motion Studies ◽  
And Performance ◽  
Flow Of Information

Purpose The purpose of this paper is to explore the applicability of lean construction (LC) concepts and tools in necessary, but non-value-added activities (NVAA) in small and medium-sized enterprises (SME). The application of the lean tools in this way facilitates the flow of information and handling material, improving productivity, quality and performance. Finally, practical results motivate a discussion on the real potential of LC principles and on the challenges related to its implementation. Design/methodology/approach The methodology makes use of direct involvement in the environment under study. Some of the activities performed were the value stream mapping and time and motion studies of the company’s process selected, identification of wastes and the proposition of improvements to be implemented. Findings The main findings are related to the benefits of the application of LC not only in value-added activities but in activities that can influence the development and workforce planning, especially for SME businesses. This company should be able to achieve better management decisions and results after implementing the LC principles, overcoming the limited resources. Originality/value This proposed method helps in overcoming the lack of systematic procedures, enabling LC in activities that not add value properly. It has the advantage of integrating existing tools and models effectively, which not only improve the shortcomings of the conventional methods but also result in more convenient calculation and application.

Lean service system design: a simulation-based VSM case study

2019 ◽  
Vol 25 (7) ◽  
pp. 1802-1821 ◽  
Author(s):  
Fatih Cavdur ◽  
Betul Yagmahan ◽  
Ece Oguzcan ◽  
Nazli Arslan ◽  
Nurbanu Sahan
Keyword(s):  
Design Methodology ◽  
Simulation Models ◽  
Public University ◽  
Decision Makers ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Future State ◽  
Simulation Based

Purpose The purpose of this paper is to present a methodology for using simulation models together with value stream mapping (VSM) for designing lean service systems and illustrate it with a case study. Design/methodology/approach The authors propose a methodology combining simulation and VSM. Simulation models for both current and future states are developed to validate the results of the corresponding maps of current and future states, respectively. Findings The results illustrate the advantages of the suggested design represented by the future state map. Additionally, using simulation models together with VSM for validating current and future states also allows decision makers to perform comprehensive analyses on the system and draw statistical conclusions. Originality/value Although some lean applications in educational services exist in previous studies, according to the best of the authors’ knowledge, this study is the first one combining VSM and simulation for the implementation of the lean concepts in the construction and technical services of a public university.

Supply chain value stream mapping: a new tool of operation management

2016 ◽  
Vol 33 (4) ◽  
pp. 518-534 ◽  
Author(s):  
Manuel F. Suarez-Barraza ◽  
José-Á Miguel-Davila ◽  
C. Fabiola Vasquez-García
Keyword(s):  
Supply Chain ◽  
Quality Management ◽  
Supply Chains ◽  
Case Studies ◽  
Operation Management ◽  
Value Stream Mapping ◽  
Business World ◽  
Content Type ◽  
Value Stream

Purpose – The issue of the supply chain has been given much attention in recent decades, both in the academic arena as well as in the business world. It has become so important that organizations have begun to directly manage the supply chain, appointing specific managers to perform this function. New challenges now include a focus on supply to determine the right time and place for product delivery. Some authors indicate a close relationship between Total Quality Management and the supply chain regarding its philosophical and operational goals and perspectives. Lee (2004) goes even further by indicating that only organizations that devise agile, adaptable and aligned supply chains will be able to continue competing in today’s environment. Therefore, observing and measuring the supply chain at all times is critical for today’s organizations. The purpose of this paper is to describe the implementation of a tool called Supply Chain Value Stream Mapping (SCVSM) in order to thoroughly understand competitive priorities of volume and delivery (On-time Delivery (OTD)) for any supply chain in organizations. Design/methodology/approach – An exploratory case study was conducted. Two manufacturing company which have been established in Mexico with a robust supply chain for at least 20 years, were selected. The paper chronicles the implementation of SCVSM in both case studies. Three methods were used to gather data: direct observation; documentary analysis and semi-structured interviews. Findings – This paper proposes a new tool for operation management called SCVSM. Its development, refinement and applied in both case studies. The evidence shows that it is possible to apply the tool (SCVSM) to visualize the variables volume and OTD in supply chains. In consequence, this research has made a small empirical contribution to the theoretical field of supply chain quality management. Research limitations/implications – This paper has the same limitations as all other case-study-based research, including analysis subjectivity and questionable generalization of findings. There may well also be a theoretical gap in the geographic region because the paper only analyzes two companies established in Mexico. Practical implications – Derived to describe both case studies on how to apply the SCVSM tool it may prove to be of value to practitioners and managers involved in the field. Similarly, a section on managerial implications has also been included. Originality/value – The study contributes to the limited existing literature on the Supply Chain Quality Management and subsequently disseminates this information in order to provide impetus, guidance and support toward increasing the development companies in an attempt to move the Mexico manufacturing sector toward world class manufacturing performance.

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.

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