Title: Feasibility study of process flow efficiency using value stream mapping and simulation applications

Authors: Muhammad Ibadurrahman; Rosmaini Ahmad

Addresses: Faculty of Mechanical Engineering and Technology, Universiti Malaysia Perlis (UniMAP), Pauh Putra Campus, 02600 Arau, Perlis, Malaysia ' Advanced Manufacturing System (AMS) Research Group, Faculty of Mechanical Engineering and Technology, Universiti Malaysia Perlis (UniMAP), Pauh Putra Campus, 02600 Arau, Perlis, Malaysia

Abstract: This paper presents a feasibility study to optimise the efficiency of a production flow. This study applied the value stream mapping (VSM) technique and simulation approach to analyse to what extent the current company improvement effort benefits the company, then proposed an extended improvement strategy based on the LM approach. Initial results identified two main problems; bottleneck issues and an imbalance workload of operators. Simulation results revealed the previous improvement efforts carried out by the company are insignificant in reducing the bottleneck issue. Simulation results indicate the new improvement proposal be able to reduce the busy time of operators at IPP workstations from 94% to 69%, and increase the operators utilisation at OBP workstations from 44% to 95%. The new proposal also shows an increment of the final productivity to 96 boxes compared to 91 boxes based on current improvements initiated by the company.

Keywords: lean manufacturing; LM; value stream mapping; VSM; simulation; 5S; line balancing; packaging.

DOI: 10.1504/IJPQM.2026.151777

International Journal of Productivity and Quality Management, 2026 Vol.47 No.2, pp.226 - 255

Received: 07 Mar 2023
Accepted: 25 Aug 2023
Published online: 19 Feb 2026 *

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