Title: Productivity improvement using value stream mapping and simulation - case studies

Authors: Jagdeep Singh; Ajay Gupta; Rejeev Trehan

Addresses: LCET, Katani-Kalan Punjab, India ' NIT Jalandhar, Punjab, India ' NIT Jalandhar, Punjab, India

Abstract: Companies are implementing lean manufacturing tools to keep their competitiveness over their competitors by improving the manufacturing system's productivity enhancement of the product. The present study has been carried out in two manufacturing industries to justify lean thinking using value stream mapping and simulation of manufacturing system processes. The study explains the necessary steps from initially identifying the product among list of products for VSM analysis to carry out value stream of the product. Current state map has been prepared with the help of brainstorming to find potential shortcomings in the entire mapped process. Future state map has been prepared to overcome current map's shortcoming; further simulation was done to analyse the effect of the change in the production line. The results are validated by using advanced quantitative tools to justify the overall improvements. Results indicated that significant reduction of lead time by 23.6% and reduction in value added time by 9% which further improves the productivity by 4.2%. Further results of fuzzy AHP indicated 22.5% contribution of VSM and simulation in overall improvement.

Keywords: lean manufacturing; LM; simulation; productivity.

DOI: 10.1504/IJBPIM.2022.128717

International Journal of Business Process Integration and Management, 2022 Vol.11 No.2, pp.109 - 128

Received: 10 Jun 2021
Accepted: 21 Jun 2021

Published online: 02 Feb 2023 *

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