Int. J. of Industrial and Systems Engineering   »   2011 Vol.8, No.2

 

 

Title: Application of value stream mapping using simulation to decrease production lead time: a Malaysian manufacturing case

 

Author: Alireza Esfandyari, Mohd Rasid Osman, Napsiah Ismail, Farzad Tahriri

 

Addresses:
Technical Faculty, Institute of Manufacturing Automation and Production Systems (FAPS), University of Erlangen-Nuremberg, Egerlandstr. 7-9, Erlangen 91058, Germany.
Faculty of Engineering, Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia, Selangor 43400 UPM, Malaysia.
Faculty of Engineering, Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia, Selangor 43400 UPM, Malaysia.
Faculty of Engineering, Center for Product Design and Manufacturing (CPDM), University of Malaya (UM), Kuala Lumpur 50603, Malaysia

 

Abstract: Lean concept has been applied across many companies which offer value and eliminate wastes. Value stream map (VSM) as one of the fundamental tools in lean concept outlines the material and information flows for a product family to reduce wastes at discrete event production routine. In this paper, the improvement of the production lead time using VSM as a technique in a Malaysian supplier, with a job shop production system, is investigated. The main contribution of this paper is reducing production lead time when the Takt Time is much higher than the highest station's cycle time, and reducing unplanned released orders. This paper evaluates the present routing events using current state map and the future state is created answering the eight standard questions. Then, a detailed simulation model was developed to verify the result from future state map and answering the questions that are unable to be addressed by VSM.

 

Keywords: VSM; value stream mapping; lean manufacturing; simulation; lead time reduction; Malaysia; Takt time; modelling.

 

DOI: 10.1504/IJISE.2011.041371

 

Int. J. of Industrial and Systems Engineering, 2011 Vol.8, No.2, pp.230 - 250

 

Available online: 20 Jul 2011

 

 

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