A framework for VSM integrated with Fuzzy QFD

2015 ◽  
Vol 27 (5) ◽  
pp. 616-632 ◽  
Author(s):  
R. Mohanraj ◽  
M. Sakthivel ◽  
S Vinodh ◽  
K.E.K. Vimal
Keyword(s):  
Quality Function Deployment ◽  
Continuous Process ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Current State ◽  
Managerial Implications ◽  
Fuzzy Qfd ◽  
Manufacturing Organization ◽  
Fuzzy Quality Function Deployment

Purpose – The purpose of this paper is to apply a framework for value stream mapping (VSM) integrated with fuzzy quality function deployment (QFD) for enabling scientific prioritization of improvement proposals to improve leanness. Design/methodology/approach – The literature was reviewed from the perspectives of VSM, QFD and fuzzy logic applications. The current state map was developed for the case component; fuzzy QFD was used for prioritizing improvement proposals and prioritized proposals were incorporated in the future state map. Findings – The approach enabled the scientific mapping of wastes with improvement proposals and thereby enabling systematic implementation of improvement proposals. The conducted pilot study resulted in 4 percent reduction in cycle time. As the lean implementation is a continuous process, furthermore improvements are expected in near future. Research limitations/implications – The study was conducted in an Indian camshaft manufacturing organization. The improvements in terms of leanness parameters were quantified. Practical implications – The findings determined from the study has practical relevance. Besides, managerial implications were also discussed. Originality/value – The study presented in this paper was conducted in a real time manufacturing environment. Hence the contributions of study are found to be valuable among academic and practicing communities.

Enhancement of value stream mapping application process through using fuzzy DEMATEL and fuzzy QFD approaches: a case study considering economic and environmental perspectives

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Hichem Aouag ◽  
Mohyiddine Soltani ◽  
Mohamed Djamel Mouss
Keyword(s):  
Value Stream Mapping ◽  
Fuzzy Decision Making ◽  
Manufacturing Processes ◽  
Application Process ◽  
Fuzzy Dematel ◽  
Content Type ◽  
Value Stream ◽  
Current State ◽  
Fuzzy Qfd ◽  
Fuzzy Quality Function Deployment

Purpose This paper aims to investigate an integrated approach that aims at enhancing the application process of value stream mapping (VSM) method. It also proposes an extended VSM called Economic and Environmental VSM(E-EVSM). The proposed approach highlights the improvement of economic and environmental performances. Design/methodology/approach The proposed approach has studied the integration of VSM, fuzzy decision-making trial and evaluation laboratory (DEMATEL) and fuzzy quality function deployment (QFD) to improve the economic and environmental performances of manufacturing processes. The VSM method is used for data collection and manufacturing process assessment, whereas fuzzy DEMATEL is used to analyse the current state map. Finally, fuzzy QFD is used to organize the improvement phase of VSM method. Findings The clear findings of this research prove the effectiveness of VSM method on the environmental and economic performances of manufacturing processes. In addition, the proposed approach will show the advantages of fuzzy DEMATEL and fuzzy QFD approaches in improving the application of the VSM method. Research limitations/implications The limitation of this study includes the lack of consideration of other dimensions such as social, technological and managerial. In addition, the proposed approach studied an average set of environmental and economic indicators. Originality/value The novelty of the proposed approach is proved by the development of an extended VSM method (E-EVSM). Also, the proposed approach contributes by a new methodology for analysing and improving the current state map of manufacturing processes.

Development of value stream map for an Indian automotive components manufacturing organization

2015 ◽  
Vol 13 (3) ◽  
pp. 380-399 ◽  
Author(s):  
S. Vinodh ◽  
T. Selvaraj ◽  
Suresh Kumar Chintha ◽  
Vimal K E K
Keyword(s):  
Product Line ◽  
Value Stream Mapping ◽  
Implementation Study ◽  
Content Type ◽  
Value Stream ◽  
Automotive Components ◽  
Current State ◽  
Line Construction ◽  
And Performance ◽  
Manufacturing Organization

Purpose – This paper aims to apply Value Stream Mapping (VSM) for enabling leanness in an Indian automotive components manufacturing organization. Design/methodology/approach – The study was initiated with the selection of product line, construction of current state map, identification of various wastes and the development of future state map. The improvement proposals were subjected to implementation and performance measures were quantified. Findings – The expected outcomes of the study include the quantification of wastes, improvement in manpower productivity, quality improvement and throughput time reduction. Research limitations/implications – The implementation study has been conducted in only one manufacturing organization. The experiences gained by the conduct of this implementation study are feasible and deployable in similar manufacturing organizations. Practical implications – The results of the study indicated that significant improvement in lean characteristics is possible as a result of the implementation of VSM. Originality/value – The paper reports a real-time study conducted in an automotive components manufacturing organization. Hence, the contributions are original.

E-rickshaws on urban streets: sustainability issues and policies

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Eijaz Ahmed Khan ◽  
Mohammed Quaddus
Keyword(s):  
Quality Function Deployment ◽  
Resource Dependency ◽  
Transport Systems ◽  
Future Research ◽  
Content Type ◽  
Urban Streets ◽  
Optimal Policies ◽  
Managerial Implications ◽  
Infrastructural Support ◽  
Fuzzy Quality Function Deployment

PurposeIn urban streets of developing countries, informal e-rickshaw operation can contribute to the development of economically viable, citizen-oriented and environmentally friendly transport systems. Even though informal e-rickshaw operation is important, significant gaps are apparent in the literature in relation to e-rickshaw sustainability issues and policies, and the development of a methodology grounded in a robust theoretical base. The current paper aims to address these gaps by integrating stakeholder theory (ST) and resource dependency theory (RDT) as we consider the linkage between e-rickshaw operation and the sustainability concept.Design/methodology/approachWe apply fuzzy quality function deployment (QFD), integrated with the 0–1 non-linear optimisation technique, to identify optimal policies for the e-rickshaw informal sector on Khulna city's urban streets in Bangladesh.FindingsThe results suggest that optimal policies should be formalised to regularise e-rickshaw operation. Appropriate supervision and monitoring; infrastructural support for battery charging, parking, battery recycling and solar panel installation; and training and development should all be provided.Research limitations/implicationsThe theoretical and managerial implications of our results are discussed, with future research suggestions presented.Originality/valueTo the best of our knowledge, no previous study has used ST and RDT in e-rickshaw sector research. We recognised that the stakeholder settings for sustainability policies can well influence the behaviour of informal e-rickshaw operators while allotting the necessary resources to this sector. This move assists researchers and policymakers to understand the stakeholders and resource dependency sustainability requirements of this sector and the implementation of the required policies.

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.

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.

Fuzzy model on selecting processes in Business Process Reengineering

2016 ◽  
Vol 22 (6) ◽  
pp. 1118-1138 ◽  
Author(s):  
Amin Hakim ◽  
Majid Gheitasi ◽  
Farzad Soltani
Keyword(s):  
Business Process ◽  
Quality Function Deployment ◽  
Business Processes ◽  
Business Process Reengineering ◽  
Process Reengineering ◽  
Content Type ◽  
Fuzzy Qfd ◽  
Fuzzy Quality Function Deployment ◽  
Gp Model ◽  
Organizational Objectives

Purpose The purpose of this paper is to present a methodology to assist enterprise decision makers (DMs) to select from a number of processes during Business Process Reengineering (BPR) according to organizational objectives. Indeed, after the identification and classification of process and illustration of the organizational objectives and criteria, the effect of each process on each objective and criterion is calculated to select the most appropriate processes for reengineering purposes. Design/methodology/approach The proposed methodology uses fuzzy quality function deployment (QFD) technique to convert the qualitative data (DM’s opinion) to quantitative ones and then calculates the effects of each process on the organizational objectives and criteria. Then, by using the result of fuzzy QFD, the amount of satisfaction of each process according to each criterion is calculated. By combining this data with other effective variables in BPR projects such as “cost” and “time,” a multi-objective goal programming (GP) model is formulated and solved to identify the most appropriate business processes. Findings In fact, a quantitative model is presented in which fuzzy QFD and GP methods are combined to help DMs to adopt an appropriate strategy for implementing BPR projects successfully by selecting proper processes for reengineering purposes. In addition, the presented model uses both qualitative and quantitative data and turns them into quantitative ones. An example is also provided to show how the model works. Research limitations/implications Following this investigation, other researchers could able to complete the model with more dynamic and local variables to enhance the accuracy of the model. Practical implications The introduced model will support organizations and managers to select appropriate processes for BPR; so in practice, the mentioned projects will be more efficient and successful. Originality/value The paper study is essential for organizations, because the presented decision-making model is based on fuzzy QFD and GP methods that enable the enterprises to select the business processes during the BPR projects easily. In this paper, a GP model is presented to create a balance between organizational satisfaction level and cost and time of implementing BPR projects considering organizational constraints. The proposed model was applied to a real case and the authors showed that it is an easy-to-use, valid, and powerful tool for implementing BPR projects.

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.

Application of lean manufacturing in automotive manufacturing unit

2020 ◽  
Vol 11 (1) ◽  
pp. 171-210 ◽  
Author(s):  
Jagmeet Singh ◽  
Harwinder Singh
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Value Added ◽  
Value Stream Mapping ◽  
Automotive Manufacturing ◽  
Content Type ◽  
Work In Process ◽  
Current State ◽  
Future State ◽  
Manufacturing Organization

Purpose This paper aims to apply lean manufacturing using value stream mapping (VSM) in the manufacturing organization (automotive suspension and fastening components section). To validate the VSM approach, simulation has been done. Design/methodology/approach VSM approach has been used to implement lean stages in the U-bolt section. Current state map was prepared and future state map has been implemented. Further, simulation has been done to compare current state and future state maps. Findings It has been found that there is 87.59% reduction in cycle time (C/T), 76.47% reduction in work-in-process (WIP) inventory, 95.41% reduction in production lead time, 66.08% increase in value added (VA) ratio, 95.78% reduction in non-value added (NVA) time, 57.14% reduction in the number of operators and 70.67% reduction in change over (C/O) time for the U-bolt section. Simulated and VSM of current and future state has observed error of 5 s. Research limitations/implications This study is based on automotive manufacturing industry situated in northern part of India. The outcome of this study is applicable only to the selected product of the manufacturing company. Originality/value This paper deals with case study part which reflects the true picture of implementation of Lean manufacturing (LM) tools in the organization.

VSM as a Tool for Mini-Audit of Information System

2014 ◽  
Vol 474 ◽  
pp. 73-78
Author(s):  
Jan Vavruška ◽  
František Manlig ◽  
František Koblasa
Keyword(s):  
Information System ◽  
Information Flow ◽  
Production Management ◽  
Business Processes ◽  
Process Analysis ◽  
Discrete Event ◽  
Control Process ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Current State

The main focus when improving business processes is on the analysis of material flow. Thorough analysis of the information flow and associated information systems is still undervalued. Working with inaccurate and/or obsolete data leads to incorrect outputs that negatively affect the entire control process. Analysis of the state of material has to go hand in hand with the information analysis. A mini audit of the information flow and information system can be carried out, which follows the classic principles of VSM (Value stream mapping), in order to make an initial analysis of the information flow and information system. Information about the current state of the process together with a measure how well it is represented by the model in the information system can be obtained thanks to this mini-audit. This article focuses on this mini-audit and briefly describes the auditing process. The details of how to create VSM maps is discussed with the main focus on an information flow where the key elements are the inputs and the outputs of the job orders for planning and production management. Attention is also focused on the form of delays in discrete-event recording in the production process which appear in the information system.

scholarly journals Improving Quality Control Process Through Value Stream Mapping

2018 ◽  
Vol 7 (2.29) ◽  
pp. 219
Author(s):  
Zulfa Fitri Ikatrinasari ◽  
Dan Kosasih
Keyword(s):  
Quality Control ◽  
Lead Time ◽  
Value Added ◽  
Maximum Efficiency ◽  
Value Stream Mapping ◽  
Process Time ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Quality Control Process

PT. AEMI is one of the growing electronic component manufacturing company. By this time, Kaizen project has been run and managed to become a culture in PT AEMI. However, the project has not integrated, comprehensive and not yet has a long-term goals. Implementation of value stream mapping (VSM) in PT AEMI is expected to make Kaizen projects more focused and to produce increasing of the maximum efficiency. In addition, VSM Kaizen is believed to make the those programs more integrated, effective and comprehensive. This study aims to: (1) create a current state mapping in the Department of Quality Control PT. AEMI, (2) identify wastes in the Department of Quality Control PT.AEMI, (3) create a future state mapping at the Department of Quality Control PT. AEMI, (4) make a plan of improvement and analyzing the application. Stages of the study were as follows: (1) identification of work processes, (2) collect and analysis of work process time, (3) analysis of the current state mapping, (4) calculate of lead time and process time, (5) analysis of value added and non value-added activities, (6) analysis of wastes, (7) make a plan of future state mapping, (8) improvement design (improvement planning), (9) implementation of improvement, (10) analysis of the implementation of improvements. The results of this study are: 1) current state mapping at QC Department shows that the total lead time of 848 minutes where there is non-value added activity of 778 minutes. 2) identify waste on the handling process where the product movement from assembly to QC for 2 minutes, movement transactions from assembly to QC for 479 minutes and the waiting time at  inspection area for 727 minutes. 3) future state mapping at QC Department shows that the total lead time of 516.5 minutes where there is non-value added activity of 446.5 minutes. 4) the improvement to do is to change the lay out where final inspection is moved from QC to manufacturing so as to result in reduce of non-value added activity by 46%. 

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