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Article

Hybrid Integrations of Value Stream Mapping, Theory of Constraints and Simulation: Application to Wooden Furniture Industry

1
Industrial Engineering Department, School of Applied Technical Sciences, German Jordanian University, Amman 11180, Jordan
2
Mechanical Engineering Department, Faculty of Engineering Technology, Al Balqa Applied University, Marka, Amman 11134, Jordan
*
Authors to whom correspondence should be addressed.
Processes 2019, 7(11), 816; https://doi.org/10.3390/pr7110816
Received: 19 September 2019 / Revised: 25 October 2019 / Accepted: 31 October 2019 / Published: 5 November 2019
(This article belongs to the Special Issue Synergies in Combined Development of Processes and Models)
This paper studies manufacturing processes in a wooden furniture manufacturing company. The company suffers from long manufacturing lead times and an unbalanced production line. To identify sources of waste and delay value stream mapping (VSM) and a discrete event simulation model is implemented. VSM is used to visualize and analyze the major processes of the company and provide quantifiable KPIs; the manufacturing lead-time and then Overall Equipment Effectiveness (OEE) settings. A discrete event simulation model is then built to analyze the company on a wider scale and provide the data required to identify bottlenecks. Building on the data gathered from the production lines and the simulation model, two-bottleneck detection methods are used, the utilization method, and the waiting time method. Then based on the comparison of the two methods a third bottleneck detection is utilized; the scenario-based method, to identify the primary and secondary bottlenecks. After the bottlenecks are identified, changes are then evaluated using the simulation model and radar charts were built based on the improved simulation model, which evaluates the effect of changes in the utilization and OEE results. This work managed to neutralize the effect of one of the main bottlenecks and minimize the effect of the other. The manufacturing utilization was increased by 15.8% for the main bottleneck resources followed by 2.4% for the second one. However, it is hard to convince the traditional administration of this small size manufacturing plant to adopt a completely revolutionizing, costly, and risky (at such level) lean manufacturing approach. This paper studies and provides a much lower in cost and verified scheme of enhancement. View Full-Text
Keywords: value stream map (VSM); simulation; OEE; bottleneck detection; wooden furniture manufacturing case study value stream map (VSM); simulation; OEE; bottleneck detection; wooden furniture manufacturing case study
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MDPI and ACS Style

Alzubi, E.; Atieh, A.M.; Abu Shgair, K.; Damiani, J.; Sunna, S.; Madi, A. Hybrid Integrations of Value Stream Mapping, Theory of Constraints and Simulation: Application to Wooden Furniture Industry. Processes 2019, 7, 816. https://doi.org/10.3390/pr7110816

AMA Style

Alzubi E, Atieh AM, Abu Shgair K, Damiani J, Sunna S, Madi A. Hybrid Integrations of Value Stream Mapping, Theory of Constraints and Simulation: Application to Wooden Furniture Industry. Processes. 2019; 7(11):816. https://doi.org/10.3390/pr7110816

Chicago/Turabian Style

Alzubi, Emad, Anas M. Atieh, Khaleel Abu Shgair, John Damiani, Sima Sunna, and Abdallah Madi. 2019. "Hybrid Integrations of Value Stream Mapping, Theory of Constraints and Simulation: Application to Wooden Furniture Industry" Processes 7, no. 11: 816. https://doi.org/10.3390/pr7110816

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