Eliminating transportation waste using the transportation value stream map

Abstract The paper reveals how lean instruments and metrics applied in transportation translates the importance of logistic visibility and shared information between shippers, brokers, carriers and customers along the supply chain management. Recreating a new transportation network emphasizes the idea of discovering practical strategies and actions of reducing muda in terms of efficiency and costs. Transportation cost has to be focused on frequency of trips, shipping size, distance travelled, guide routes and deficient rates. One of the objectives of the research was the analysis of the transport efficiency using the Value Stream Mapping as an important lean tool used by many practitioners to identify sources of waste and to propose alternatives of improvement. As a first conclusion of the study, transportation cannot be analyzed like a distinct part of the supply chain, therefore, VSM had to be considered, structured and visualized as linked processes of wasteful activities that need to be measured and improved. The transportation network design reflects the geographic distribution conditions, the frequency and size of the orders, the gaps between the in-transit activities and non-intransit activities. Waste identification research was focused on elaboration of Transportation Visual Map starting with main activities such as: shipment loading, transporting goods to destination, unloading processes, and transportation back to the base and handling the paperwork. MOVE Measure was the new metrics that determined the transportation efficiency in terms of availability, performance and quality, all the factors being expressed in percentage. The results of the research showed the importance of using the VSM tool in transforming the transportation segment of the supply chain from a non-value- adding activity into an optimized value- adding process.

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Lean Thinking to Foster the Transition from Traditional Logistics to the Physical Internet

Sustainability ◽

10.3390/su12156053 ◽

2020 ◽

Vol 12 (15) ◽

pp. 6053

Author(s):

Vanessa Rodríguez Cornejo ◽

Ángel Cervera Paz ◽

Luis López Molina ◽

Víctor Pérez-Fernández

Keyword(s):

Supply Chain ◽

Waiting Times ◽

Value Stream Mapping ◽

Lean Thinking ◽

Value Stream ◽

A Value ◽

Physical Internet ◽

The Right ◽

The Relationship ◽

Value Stream Map

This paper studies the relationship between Lean paradigms and the Physical Internet (PI). Lean thinking is a philosophy that allows one to obtain the right amount of the right items in the right place at the right time; it seeks to minimize waste and is flexible to change. In fact, applying Lean not only helps to reduce costs, but it also adds value and improves results across the supply chain. By using a value stream map, we can map the process from the supply chain to the customer, while trying not to add value activities. Such activities include excessive production, overstorage, waiting times poorly adjusted to needs, defects and rejects that require reprocessing, and, finally, unnecessary transport and movements. Storage, waiting times, and unnecessary transport and movements are at the core of the PI. A value stream map can also help to identify empty transport and unnecessary CO2 emissions. This study analyzes value stream mapping as a tool that can enable the objectives of the different Alliance for Logistics Innovation through Collaboration (ALICE) roadmaps for logistics innovation to be achieved, and can also allow PI principles to be reached on the established dates.

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Improving the performance of a Malaysian pharmaceutical warehouse supply chain by integrating value stream mapping and discrete event simulation

Journal of Modelling in Management ◽

10.1108/jm2-07-2019-0159 ◽

2020 ◽

Vol ahead-of-print (ahead-of-print) ◽

Cited By ~ 1

Author(s):

Ahmed Abideen ◽

Fazeeda Binti Mohamad

Keyword(s):

Supply Chain ◽

Lead Time ◽

Discrete Event ◽

Integrated Approach ◽

Value Stream Mapping ◽

Content Type ◽

Value Stream ◽

Future State ◽

The Future ◽

Value Stream Map

Purpose Lean implementation is vastly incorporated in core manufacturing processes; however, its applicability in the supply chain and service industry is still in its infancy. To acquire performance excellence and thrive in the global competitive market, many firms are adopting newer methodologies. But, there is a stringent need for production simulation systems to analyze supply chains both inbound and outbound. The era of face validation is slowly disappearing. Lean tools and procedures that provide future state assumptions need advanced tools and techniques to measure, quantify, analyze and validate them. The purpose of this study is to enable dynamic quantification and visualization of the future state of a warehouse supply chain value stream map using discrete event simulation (DES) technique. Design/methodology/approach This study aimed to apply an integrated approach of the value stream mapping (VSM) and DES in a Malaysian pharmaceutical production warehouse. The main focus is diverted towards reducing the warehouse supply chain lead time by initially constructing a supply chain value stream map (both present state and future state) and integrating its data in a DES modelling and simulation software to dynamically visualize the changes in future state value stream map. Findings The DES simulation was able to mimic the future state lead time reductions successfully, which assists in better decision-making. Improvements were seen related to total lead time, process time, value and non-value-added percentage. Warehouse performance metrics such as receiving, put away and storage rates were substantially improved along with pallet processing time, worker and forklift throughput usage percentage. Detailed findings are clearly stated at the end of this paper. Research limitations/implications This study is limited to the warehouse environment and further additional process models and functional upgrades in the DES software systems are very much needed to directly visualize and quantify all the possible Lean assumptions such as radio frequency image identification/Andon (Jidoka), 5S, Kanban, Just-In-Time and Heijunka. However, DES has a leading edge in extracting dynamic characteristics out of a static VSM timeline and capture details on discrete events precisely by picturizing facility modification and lead time related to it. Practical implications This paper includes all the fundamental pharmaceutical warehouse supply chain processes and the simulations of the future state VSM in a real-life context by successfully reducing supply chain lead time and allowing managers in inculcating near-optimal decision-making, controlling and coordinating warehouse supply chain activities as a whole. Social implications This integrated approach of DES and VSM can involve managers and top management to support the adoption of anticipated changes. This study also has the potential to engage practitioners, researchers and decision-makers in the warehouse industry. Originality/value This study involves a powerful DES software package that can mimic the real situation as a virtual simulation and all the data and model building are based on a real warehouse scenario in the pharmaceutical industry.

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A lean approach to optimize BIM information flow using value stream mapping

Journal of Information Technology in Construction ◽

10.36680/j.itcon.2019.025 ◽

2019 ◽

Vol 24 ◽

pp. 472-488

Author(s):

Martin Michaud ◽

Eva-Charlotte Forgues ◽

Vincent Carignan ◽

Daniel Forgues ◽

Claudiane Ouellet-Plamondon

Keyword(s):

Information Flow ◽

Waste Reduction ◽

Value Stream Mapping ◽

Building Information Modelling ◽

Information Platform ◽

Value Stream ◽

Virtual Integration ◽

Reduction Strategies ◽

Building Information ◽

Shared Information

Building Information Modelling (BIM) was introduced in the Architecture, Engineering and Construction (AEC) industry as a shared information platform that aims to improve productivity through better collaboration. The assumption is that a virtual integration of information among project stakeholders would reduce the issues around the fragmented nature of the processes that still prevail in the construction field. This paper aims to highlight the sources of waste in the information flows between an architecture firm, a Mechanical, Electrical and Plumbing (MEP) engineering firm, a general contractor (GC) and a MEP subcontractor (SC) in a BIM project – an aspect of waste little covered in the Lean literature. The focus is on the MEP process from early design to the final product. This research contributes to the identification of the main barriers to information flow, including the conflicts and waste sources that emerge from using BIM, as well as to the identification of emerging successes. Moreover, the findings offer practical implications by providing a visual of the patterns emerging from the use of BIM. Finally, by providing potential waste reduction strategies such as Value Stream Mapping (VSM) this work allows construction actors to identify and reduce sources of waste in their processes.

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Improving Efficiency and Patient Satisfaction in a Peripherally Inserted Central Catheter Center Using Lean-Based Methodology

Journal of the Association for Vascular Access ◽

10.1016/j.java.2014.07.004 ◽

2014 ◽

Vol 19 (4) ◽

pp. 244-255 ◽

Cited By ~ 6

Author(s):

Ying Zhu ◽

Zhenqi Lu ◽

Hongqin Dai

Keyword(s):

Lean Manufacturing ◽

Value Stream Mapping ◽

Cancer Center ◽

Peripherally Inserted Central Catheter ◽

Central Catheter ◽

Value Stream ◽

Root Cause ◽

Number Of Patients ◽

Future Value ◽

Value Stream Map

Abstract Background: The peripherally inserted central catheter implantation and maintenance process was optimized at Shanghai Fu Dan University Cancer Center using lean-based methodology. Problems addressed were coping with capacity limitations and streamlining the process of patient care to reduce potential complications associated with delays in catheter administration. These clinical processes were evaluated with regard to pretreatment areas—such as booking, waiting, and patient education—and solutions were recommended to the problems that were identified. Methods: Lean methodology was used under actual clinical settings to improve the clinical process, using observations, patient surveys, interviews, data analysis, and a kaizen workshop. Three tools were applied from lean methodology: value stream mapping, bottleneck calculation, and fishbone root cause analysis. The philosophy of kaizen was used to enhance teamwork, boost morale, and encourage all members of the frontline nursing team and administration leaders to contribute ideas and suggestions for improvement. Results: A value stream map and a redesigned future value stream map were plotted at the workshop to identify problems related to inefficiency and waste and to aid in proposing solutions. Implementation of these solutions resulted in smooth and steady patient distributions on days with the largest patient volume during a typical week and an increase of 30% in the number of patients that could be seen in a week. Conclusions: The economic methodology of lean manufacturing, especially value stream mapping, can be a powerful tool for visualizing and better understanding processes to reduce waste and reengineer a standardized workstream in settings where peripheral intravenous central catheters are placed.

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Lean Production on Chili Pepper Supply Chain Using Value Stream Mapping

MIMBAR Jurnal Sosial dan Pembangunan ◽

10.29313/mimbar.v34i2.3458 ◽

2018 ◽

Vol 34 (2) ◽

pp. 311-320

Author(s):

Tomy Perdana ◽

Fernianda Rahayu Hermiatin ◽

Ajeng Sesy Nur Pratiwi ◽

Tetep Ginanjar

Keyword(s):

Supply Chain ◽

Research Result ◽

Chili Pepper ◽

Value Stream Mapping ◽

Chilli Pepper ◽

Operation System ◽

Waste Products ◽

Value Stream ◽

Efficiency And Effectiveness ◽

Kanban System

In the globalization economic development, most of industries have been developing strategies to improve efficiency in their production processes. Meanwhile, chili pepper supply chain is still not aware about efficiency and effectiveness in its management. Most actors in chili pepper supply chain face several obstacles, i.e. losses, waste products, and inefficiency in delivery time. This research is focused on the development of chili pepper supply chain performance using Value Stream Mapping (VSM) analysis and aims to create a new key system to develop efficiency and effectiveness. VSM is used as an instrument to enhance comparative advantage in wildly industries. VSM in chili pepper involves operation system such as 6S, Volkswagen production system, visual workplace, quick changeover system, and Hiejunka Kanban system. Those techniques are applied to reduce waste in chili pepper supply chain. The research result shows that chilli pepper supply chain should explore the implementation of VSM.

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Transportation Cost Reduction and Simulation of Entire Flow Process along with Value Stream Mapping

International Journal of Advanced Science and Engineering ◽

10.29294/ijase.4.2.2017.585-591 ◽

2017 ◽

Vol 4 (2) ◽

pp. 585

Author(s):

U. Mohamed Faizal ◽

V. Ajith

Keyword(s):

Cost Reduction ◽

Transportation Cost ◽

Value Stream Mapping ◽

Flow Process ◽

Value Stream ◽

Entire Flow

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Construction of the Optimization Model of Cargo Transport Network

E3S Web of Conferences ◽

10.1051/e3sconf/202126103013 ◽

2021 ◽

Vol 261 ◽

pp. 03013

Author(s):

Yanyan Kong ◽

Benfang Tian ◽

Qingyang Wang ◽

Donghui Liu ◽

Yunfei Gao ◽

...

Keyword(s):

Optimization Model ◽

High Efficiency ◽

Transportation Network ◽

Transportation Cost ◽

Circulation System ◽

Time Cost ◽

Transportation Modes ◽

Consumption Cost ◽

The Cost ◽

In Transit

The transportation is gradually integrated into the circulation system of bulk goods, and developing and growing. Transportation has the advantages of high efficiency, high quality and green environment, In time, efficiency and cost than the traditional bulk transport has certain advantages. This paper analyzes the cost of logistics transportation network, which mainly includes transportation cost in transit, transit cost, time cost of cargo transportation and special cost. This paper discusses in detail the transportation cost, transit cost, time cost and carbon consumption cost of different transportation modes in the process of “scattered transformation”, and constructs the optimization model of” scattered transformation “transportation network with the least comprehensive transportation cost including the above costs.

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A roadmap for improving the manifacture of automotive heat exchangers through value stream mapping

10.51415/10321/3528 ◽

2019 ◽

Author(s):

◽

Kate Lusiba

Keyword(s):

Production Process ◽

Heat Exchangers ◽

Line Balancing ◽

Value Stream Mapping ◽

Automotive Manufacturing ◽

Value Stream ◽

Final Assembly ◽

Work In Process ◽

Value Stream Map

Lean manufacturing is an optimum approach for the reduction and elimination of waste within an organization. The case study company is based in South Africa and produces heat exchangers through main processes or fractals, which include pre-assembly, core building, brazing and final assembly. A walk through the plant showed that there was a large amount of inventory awaiting final assembly and that the brazing furnace often waited for material from core building. This was an indication that there could be an imbalance between the three fractals in terms of cycle time. Thus, the aim of this study was to improve the manufacturing processes for heat exchangers at the automotive manufacturing company through the deployment of value stream mapping, subsequent line balancing and developing a roadmap for reduction of waste. The case study research strategy was adopted for the study since it provided an in-depth view of phenomena. The first objective was to outline the production flow for the manufacture of automotive heat exchanger parts. The method used was a walk through the plant and observations were made to gain an understanding of the production steps from logistics production planning to shipping of the finished goods, and subsequently to a mapping-out of the production process flow was undertaken. The results showed that there was a large amount of inventory awaiting final assembly and that the brazing furnace often waited for material from core building. It was concluded that there was need to conduct a detailed process analysis to identify sources of waste. The second objective was to conduct value stream mapping for assessing the value- and non-value-adding activities in the manufacture of automotive heat exchangers components. A value stream map was developed through walking to Gemba and mapping out the production process, collecting data and pinpointing waste activities or areas to be improved. The kaizen flashes from the value stream map also revealed that operators were not fully utilizing the capacity of the bottleneck workstations. It was concluded that two instead of one planning points, and inefficiency at assembly were root causes of the high work-in-process level. The third objective was to conduct a line balancing analysis for the three production fractals. The method used was a Pareto analysis for evaluating the products, analysing the product mix and line balancing analysis of the production line. The results revealed that the furnace was run on two shifts while the subsequent assembly and preceding core building were running on three shifts causing a work-in-process build-up, thereby resulting in line imbalance. It was concluded that it was imperative to change the scheduling approach, and adopt one that prioritised and spread the cores that had relatively short cycle times, and also reduce downtime, change-over time as well as additional time for scrap and defects, and a future-state balance chart revealed that the fractals imbalance had been reduced. The fourth objective was to develop a roadmap for reduction of waste in the manufacture of car heat exchangers components. The method used was to develop proposals and assess the feasibility and cost implications of implementing each option. Recommendations were made for continuous process improvement and a roadmap for reduction of waste was proposed. In order to improve the output of assembly, training for the operators was recommended since it would also enable the removal of the second planning point at assembly. Further research could also be conducted to develop an optimal scheduling algorithm for allocation of products to work centres to ensure high utilization of work centres and reduce work-in-process inventory.

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