A lean manufacturing strategy using Value Stream Mapping, the Unified Modeling Language, and discrete event simulation

2012 ◽  
Author(s):  
Mariagrazia Dotoli ◽  
Maria Pia Fanti ◽  
Giorgio Iacobellis ◽  
Giuliana Rotunno
Keyword(s):  
Discrete Event Simulation ◽  
Lean Manufacturing ◽  
Discrete Event ◽  
Unified Modeling Language ◽  
Value Stream Mapping ◽  
Modeling Language ◽  
Manufacturing Strategy ◽  
Unified Modeling ◽  
Value Stream ◽  
Event Simulation

scholarly journals Supporting Discrete Event Simulation with 3D Laser Scanning and Value Stream Mapping: Benefits and Drawbacks

Procedia CIRP ◽  
2018 ◽  
Vol 72 ◽  
pp. 1536-1541 ◽  
Author(s):  
Daniel Nåfors ◽  
Maja Bärring ◽  
Maxime Estienne ◽  
Björn Johansson ◽  
Mats Wahlström
Keyword(s):  
Discrete Event Simulation ◽  
Laser Scanning ◽  
Discrete Event ◽  
Value Stream Mapping ◽  
3D Laser Scanning ◽  
Value Stream ◽  
Event Simulation

scholarly journals Improving productivity of road surfacing operations using value stream mapping and discrete event simulation

2017 ◽  
Vol 17 (3) ◽  
pp. 294-323 ◽  
Author(s):  
Zeeshan Aziz ◽  
Rana Muhammad Qasim ◽  
Sahawneh Wajdi
Keyword(s):  
Discrete Event Simulation ◽  
Discrete Event ◽  
Primary Data ◽  
Value Stream Mapping ◽  
Research Approach ◽  
Production Rates ◽  
Related Factors ◽  
Content Type ◽  
Value Stream ◽  
Event Simulation

Purpose The purpose of this paper is to investigate the integration of discrete event simulation (DES) and value stream mapping (VSM) to enhance the productivity of road surfacing operations by achieving high production rates and minimum road closure times. Highway infrastructure is one of the most valuable assets owned by the public sector. The success of national and local economies as well as quality of life of the general public depend on the efficient operations of highways. Ensuring smooth traffic operations requires maintenance and improvements of the highest standard. Design/methodology/approach Research approach involved the use of primary data collected from direct observation, interviews, review of archival records and productivity databases. Based on this, process maps and value stream maps were developed which were subsequently used to produce discrete event simulation models for the exploration of different optimisation scenarios. Findings This research highlights the synergistic relationship between VSM and DES in driving innovation in construction processes. Identified factors that affect roadworks process productivity include machine, manpower, material, information, environment and method-related factors. A DES model is presented to optimise the process and increase the production rates. A hybrid DES-VSM approach ensures an integrated approach to process optimisation. Research limitations/implications This study is an application of hybrid version of previously published DES-VSM framework in the manufacturing sector. The present study has extended and tested its applicability within road surfacing operations. The different what-if scenarios presented in this paper might not be applicable to other parts of the world owing to various constraints. The study has focused on addressing the waste production inherent in pavement laying process. Even though external variables could possibly influence pavement process, those were ignored to allow for in-depth focus on the process under consideration. Practical implications Road users are one of the most important stakeholders that will benefit from the positive implications of this study. Private resurfacing companies and transport departments can optimise their overall process and style of working by comparing their end-to-end process and work plans with the ones mentioned in this paper. It will boost the productivity of equipment like planners, pavers and other machines used for resurfacing operations. Originality/value Existing approaches to process modelling such as VSM and process diagrams are constrained by their effectiveness in the analysis of dynamic and complex processes. This study presents a DES-based approach to validate targeted improvements of the current state of road surfacing processes and in exploration of different optimisation scenarios.

scholarly journals Hybrid Integrations of Value Stream Mapping, Theory of Constraints and Simulation: Application to Wooden Furniture Industry

Processes ◽  
2019 ◽  
Vol 7 (11) ◽  
pp. 816 ◽  
Author(s):  
Emad Alzubi ◽  
Anas M. Atieh ◽  
Khaleel Abu Shgair ◽  
John Damiani ◽  
Sima Sunna ◽  
...  
Keyword(s):  
Simulation Model ◽  
Discrete Event Simulation ◽  
Discrete Event ◽  
Detection Methods ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Event Simulation ◽  
Discrete Event Simulation Model ◽  
Bottleneck Detection ◽  
Wooden Furniture

This paper studies manufacturing processes in a wooden furniture manufacturing company. The company suffers from long manufacturing lead times and an unbalanced production line. To identify sources of waste and delay value stream mapping (VSM) and a discrete event simulation model is implemented. VSM is used to visualize and analyze the major processes of the company and provide quantifiable KPIs; the manufacturing lead-time and then Overall Equipment Effectiveness (OEE) settings. A discrete event simulation model is then built to analyze the company on a wider scale and provide the data required to identify bottlenecks. Building on the data gathered from the production lines and the simulation model, two-bottleneck detection methods are used, the utilization method, and the waiting time method. Then based on the comparison of the two methods a third bottleneck detection is utilized; the scenario-based method, to identify the primary and secondary bottlenecks. After the bottlenecks are identified, changes are then evaluated using the simulation model and radar charts were built based on the improved simulation model, which evaluates the effect of changes in the utilization and OEE results. This work managed to neutralize the effect of one of the main bottlenecks and minimize the effect of the other. The manufacturing utilization was increased by 15.8% for the main bottleneck resources followed by 2.4% for the second one. However, it is hard to convince the traditional administration of this small size manufacturing plant to adopt a completely revolutionizing, costly, and risky (at such level) lean manufacturing approach. This paper studies and provides a much lower in cost and verified scheme of enhancement.

scholarly journals Measuring lean implementation for maintenance service companies

2016 ◽  
Vol 7 (1) ◽  
pp. 35-61 ◽  
Author(s):  
Stephan J. de Jong ◽  
Wouter W.A. Beelaerts van Blokland
Keyword(s):  
Transaction Cost ◽  
Discrete Event Simulation ◽  
Continuous Improvement ◽  
Lean Manufacturing ◽  
Discrete Event ◽  
Asset Specificity ◽  
Lean Implementation ◽  
Content Type ◽  
Event Simulation ◽  
Maintenance Service

Purpose – Implementation of lean manufacturing is currently performed in the production industry; however, for the airline maintenance service industry, it is still in its infancy. Indicators such as work in process, cycle time, on-time performance and inventory are useful indicators to measure lean implementation; however, a financial economic perspective taking fixed assets into consideration is still missing. Hence, the purpose of this paper is to propose a method to measure lean implementation from a fixed asset perspective for this type of industry. With the indicators, continuous improvement scenarios can be explored by value stream discrete event simulation. Design/methodology/approach – From literature, indicators regarding asset specificity to measure lean implementation are found. These indicators are analysed by a linear least square method to know if variables are interrelated to form a preliminary model. The indicators are tested by value stream-based discrete event simulation regarding continuous improvement scenarios. Findings – With the new found lean transaction cost efficiency indicators, namely, turnover, gross margin and inventory pre-fixed asset (T/FA, GM/FA and I/FA, respectively), it is possible to measure operation performance from an asset specificity perspective under the influence of lean implementation. Secondly, the results of implementing continuous improvement scenarios are measured with the new indicators by a discrete event simulation. Research limitations/implications – This research is limited to the airline maintenance, repair and overhaul (MRO) service industry regarding component repair. Further research is necessary to test the indicators regarding other airline MRO service companies and other sectors of complex service industries like health care. Practical implications – The lean transaction cost efficiency model provides the capability for a maintenance service company to simulate the effects of process improvements on operation performance for service-based companies prior to implementation. Social/implications – Simulation of a Greenfield process can involve employees with possible changes in processes. This approach supports the adoption of anticipated changes. Originality/value – The found indicators form a preliminary model, which contributes to the usage and linkage of theories on lean manufacturing and transaction cost theory – asset specificity.

scholarly journals Quantifying the Impact of Inspection Processes on Production Lines through Stochastic Discrete-Event Simulation Modeling

Modelling ◽  
2021 ◽  
Vol 2 (4) ◽  
pp. 406-424
Author(s):  
Pablo Martinez ◽  
Rafiq Ahmad
Keyword(s):  
Discrete Event Simulation ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Discrete Event ◽  
Production Lines ◽  
Event Simulation ◽  
Inspection Systems ◽  
The Cost ◽  
Multistage Production ◽  
The Impact

Inspection processes are becoming more and more popular beyond the manufacturing industry to ensure product quality. Implementing inspection systems in multistage production lines brings many benefits in productivity, quality, and customer satisfaction. However, quantifying the changes necessary to adapt the production to these systems is analytically complicated, and the tools available lack the flexibility to visualize all the inspection strategies available. This paper proposed a discrete-event simulation model that relies on probabilistic defect propagation to quantify the impact on productivity, quality, and material supply at the introduction of inspection processes in a multistage production line. The quantification follows lean manufacturing principles, providing from quite basic quantity and time elements to more comprehensive key performance indicators. The flexibility of discrete-event simulation allows for customized manufacturing and inspection topologies and variability in the tasks and inspection systems used. The model is validated in two common manufacturing scenarios, and the method to analyze the cost-effectiveness of implementing inspection processes is discussed.

scholarly journals SIMULATION SERVICE PROVIDING IN A DISTRIBUTED SIMULATION ENVIRONMENT

2014 ◽  
pp. 38-45
Author(s):  
Alexey Cheptsov
Keyword(s):  
Distributed Simulation ◽  
Discrete Event ◽  
Unified Modeling Language ◽  
Simulation Environment ◽  
Simulation Framework ◽  
Web Based ◽  
Unified Modeling ◽  
Event Simulation ◽  
Complex Dynamic Systems ◽  
Unified Process

Simulation of complex dynamic systems is an interdisciplinary problem. To solve this problem the author suggests a distributed simulation environment as a new form of simulation means system organization that provides web-based distributed simulation of engineering and industrial tasks as simulation services using Discrete Event Simulation Framework on the basis of Grid infrastructure. The Unified Process of Simulation Services Development based on Unified Modeling Language is proposed.

A Modeling and Simulation of Production Process in Subassembly Lines at a Shipyard

2004 ◽  
Vol 20 (02) ◽  
pp. 79-83
Author(s):  
Jong Gye Shin ◽  
Kwang Kook Lee ◽  
Jong Hun Woo ◽  
Won Don Kim ◽  
Jang Hyun Lee ◽  
...  
Keyword(s):  
Production Process ◽  
Process Model ◽  
Discrete Event ◽  
Unified Modeling Language ◽  
Simulation Method ◽  
Unified Modeling ◽  
Event Simulation ◽  
Modeling Methodology ◽  
Proposed Model ◽  
Welding Processes

In order to simulate material flow in a subassembly line at a shipyard, the product, process, and resources are modeled for the subassembly process. The subassembly line is selected from a large shipyard and consists of several subprocesses, such as base joining, piece alignment, tack welding, and robot welding processes. The analysis and modeling procedure were carried out using the Unified Modeling Language (UML), an object-oriented modeling methodology, and Integration Definition (IDEF), a functional modeling tool. Initially, the characteristics of the shop resources were analyzed using the shipyard data and the layout of the subassembly line was designed with the resources. A production process was then modeled using the resources and the layout. The production process modeling of the subassembly lines was performed using the discrete event simulation method. Using the constructed resource and process model, the productivity and efficiency of the line were investigated. Variations in the resource performance, such as a new welding robot and the number of workers, were examined to simulate changes in productivity. It can be seen that bottlenecks occur in different places according to the nature of new resources. The proposed model is viewed three-dimensionally in a virtual environment so that space allocations for the resources and interferences between objects can be easily investigated.

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