Title: Achieving lean through value stream mapping with constraint programming and simulation technique for complex production systems

Authors: Shyamal Samant; Ravi Prakash

Addresses: Department of Mechanical Engineering, Amity School of Engineering and Technology, Noida, India ' Amity Institute of Technology, Noida, Uttar Pradesh, India

Abstract: Lean manufacturing helps companies achieve improved productivity, quality, reduced lead time and cost reduction. This leads to the competitiveness of manufacturing systems. To achieve lean many tools are available. Value stream mapping (VSM) occupies an important place among the available tools. However, VSM as a tool suffers from many shortcomings. It can only give a static snapshot of the situation. It cannot be easily applied to achieve lean in complex production stream, e.g., manufacture of complete product, assembly operations involving multi-product, multi-level bill of materials (BOM) scenarios. This paper proposes an innovative framework to achieve lean. The proposed approach integrates CPLEX optimisation, Arena simulation and lean box score method for achieving lean in complex production streams. A case of pump manufacturer is discussed to demonstrate the proposed framework.

Keywords: value stream mapping; VSM; lean manufacturing; constraint programming; simulation; lean management.

DOI: 10.1504/IJISE.2021.112470

International Journal of Industrial and Systems Engineering, 2021 Vol.37 No.1, pp.119 - 148

Received: 13 Feb 2019
Accepted: 10 Jun 2019
Published online: 19 Jan 2021 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article