Search Results (41)

We developed an optimization method with value stream mapping (VSM), dynamic system simulation, and processing time prediction. First, VSM was used to quantitatively analyze the production process, identify value-added and non-value-added activities, and build a mathematical model to describe the flow of resources and waste at various stages. Then, a discrete event simulation (DES) was applied to simulate changes in the production process under different improvement conditions and to assess the effect of improved production efficiency using stochastic event modeling. As a result, we identified potential bottlenecks based on the flow of resources and waste sources throughout the production process and proposed improvement solutions for higher efficiency based on production simulations by predicting processing times for stability of production plans. Full article

Although Thailand is one of the world’s leading exporters of frozen shrimp, the production process and management of the production line remain problematic, due to high operation costs, which may make it difficult for Thailand to compete with other export countries. The aim of this research was therefore to improve the production process for frozen shrimp. Value stream mapping (VSM) was utilized to identify the activity processes, from raw material to the customer, and line balancing (LB) was employed to arrange the production line to achieve process improvements. The ECRS (Eliminate, Combine, Rearrange, Simplify) technique was applied to manage and ameliorate the production process. The result was a suitable production process for frozen shrimp in which the profitability to entrepreneurs can be increased through lean improvement techniques. VSM revealed that the efficiency of the total cycle time could be decreased by approximately 61.72%, and that the lead time could be reduced by about 48.8%. Improvements to the frozen shrimp process through LB could yield an accuracy of up to 90.50%. The ECRS technique helped in arranging new processing to achieve improvements; value-added (VA), non-value-added (NVA), and necessary non-value-added (NNVA) tasks showed that the efficiency of the production process could rise to 46.37%, 25%, and 92.85%, respectively. Entrepreneurs will be able to run their manufacturing processes and achieve high production efficiency in the future using the methodologies and management practices described here. Full article

The petroleum industry has been a key driver in the development of the world economy yet continues to attract increasing criticism due to its negative environmental impact via greenhouse gas emissions, resource inefficiency, and waste. Integrating lean and green practices is fast becoming a transformative approach to tackling these issues as it integrates process optimization with sustainability principles. This review paper examined the existing literature on lean and green integration, highlighting its benefits, models, critical success factors, and a roadmap for its implementation. Also, it identified sustainability challenges and offered strategic solutions. The findings showed that integrating lean and green offers potential for both process optimization and waste and carbon footprint reduction, particularly for the petroleum industry in Sub-Saharan Africa (SSA). This can be achieved by using appropriate tools and models. Sustainable value stream mapping (Sus-VSM) is a strategic tool that highlights the importance of sustainability metrics. These sustainability metrics address the implementation challenges of the convectional value stream mapping tool (VSM). This paper is one of the few initiatives to promote lean–green integration within the petroleum industry. Full article

This study investigates the transformation of e-commerce warehouse operations by integrating Lean Six Sigma tools to enhance efficiency and sustainability. Beginning with Value Stream Mapping (VSM) to identify inefficiencies, followed by a Hoshin Kanri plan to align improvement initiatives with strategic objectives, the study implemented measures such as pallet pooling, process standardization, automation in inspection and picking, layout optimization, and Kanban systems for continuous improvement. A case study of a local e-commerce warehouse specializing in medical devices and healthcare products identified 29 activities across receiving, inspection, storing, picking, packing, and shipping, highlighting inefficiencies addressed through Lean-driven initiatives. These efforts resulted in a 23% reduction in total lead time, doubled value-added time, and significant improvements in inspection, picking, packing, and automation, reducing delays, lowering costs, and enhancing workflow. The study fills a gap in the literature by integrating multiple Lean tools and utilizing the Critical to Quality (CTQ) matrix to ensure sustainable improvements in e-commerce warehousing, emphasizing the strategic value of Lean Six Sigma in creating efficient, customer-focused operations. Full article

Purpose: Addressing sustainability challenges in additive manufacturing (AM) is critical due to high energy consumption and waste. Optimising AM operations is vital for sustainability. However, the existing literature lacks practical examples for AM companies on how to enhance sustainability. To address this gap, a case study within an AM firm was conducted. Design approach: Using the analytical hierarchy process (AHP), sustainability key performance indicators (KPIs) were identified, aligned with the firm’s strategic objectives. Sustainable value stream mapping (Sus-VSM) analysed the production process for sustainability performance. A sustainability strategy map (SSM) was created based on the five perspectives of the 4th generation balanced scorecard (BSC) approach and the results from the case study. Findings: The research identified optimisation areas in the multi-jet-fusion (MJF) process, crafted tailored sustainability KPIs, and developed a SSM to seamlessly integrate sustainability initiatives into the company’s vision. Value: This contribution provides a structured methodology for selecting KPIs and offers a holistic approach to implementing Sus-VSM within the AM industry. The manuscript emphasises the need to incorporate a fifth perspective into the BSC and proposes a framework for developing a SSM. This study aims to guide AM companies toward a more environmentally responsible and socially conscious approach to manufacturing. Full article

City manufacturing has once again become one of the priority areas for the sustainable development of smart cities thanks to the use of a wide range of green technologies and, first of all, additive technologies. Shortening the supply chain between producers and consumers has significant effects on economic, social, and environmental dimensions. Zoning of city multifloor manufacturing (CMFM) in areas with a compact population in large cities in the form of clusters with their own city logistics nodes (CLNs) creates favorable conditions for promptly meeting the needs of citizens for goods of everyday demand and for passenger and freight transportation. City multifloor manufacturing clusters (CMFMCs) have been already studied quite a lot for their possible uses; nevertheless, an identified research gap is related to supply chain design efficiency concerning CMFMCs. Thus, the main objective of this study was to explore the possibilities of lean supply chain management (LSCM) as the integrated application of lean manufacturing (LM) approaches and I4.0 technologies for customer-centric value stream management based on eliminating all types of waste, reducing the use of natural and energy resources, and continuous improvement of processes related to logistics activities. This paper presents a decision support model for LSCM in CMFMCs, which is a mathematical deterministic model. This model justifies the minimization of the number of road transport transfers within the urban area and the amount of stock that is stored in CMFMC buildings and in CLNs, and also regulating supplier lead time. The model was verified and validated using appropriately selected test data based on the case study, which was designed as a typical CMFM manufacturing system with various parameters of CMFMCs and urban freight transport frameworks. The feasibility of using the proposed model for value stream mapping (VSM) and managing logistics processes and inventories in clusters is discussed. The findings can help decisionmakers and researchers improve the planning and management of logistics processes and inventory in clusters, even in the face of unexpected disruptions. Full article

Background/Objectives: The implementation of information quality value stream maps (IQ-VSMs) in food animal production systems can increase our understanding of the opportunities and challenges when using laboratory testing for antimicrobial resistance (AMR) to support antimicrobial stewardship (AMS). Our objectives were to (1) explore the implementation of information quality value stream mapping as a continuous improvement tool to inform decisions for bovine respiratory disease (BRD) management and AMS and (2) apply the information quality dimensions to identified Kaizen opportunities for the integration of laboratory data into BRD management systems to assess the appropriateness of BRD treatment plans in western Canadian feedlot production. Methods: A ‘Current State’ IQ-VSM outlined the processes, available information, information processing steps, and control decisions contributing to BRD management and treatment in commercial western Canadian feedlots, recognizing that laboratory BRD pathogens and AMR data are typically not part of BRD management. Results: The ‘Future State’ IQ-VSM incorporated Kaizen opportunities for improvement, including (i) the strategic collection of respiratory samples from representative samples of calves for laboratory analysis, regardless of clinical BRD status, (ii) compilation of laboratory data at the pen and feedlot levels, and (iii) analysis of pen- and feedlot-level laboratory data to inform the veterinarian’s assessment of the appropriateness of current BRD treatment plans. Conclusions: The IQ-VSMs provided a valuable framework to visualize the integration of BRD pathogen and AMR laboratory data to support AMS and address any potential future testing requirements. Full article

The current market is highly competitive, and customers are increasingly demanding. In this context, organizations need to adopt tools that enhance process efficiency to ensure competitiveness. This report aims to implement Lean tools, specifically Value Stream Mapping (VSM) and complementary tools, to optimize the production process in the metal treatment industry. A case study was conducted, beginning with a brief sector and process recognition, followed by an analysis of production stages using VSM. Value-added activities, non-value-added activities, and waste were identified. The current VSM revealed a Lead Time (LT) of approximately 336 h (14 days), value-added activities (VA) of 21 h, and a process cycle efficiency (PCE) of 6.29%. Improvement actions were proposed to reduce waste and increase competitiveness. After implementation, the LT decreased to approximately 318 h (13 days), VA increased to 23 h, and process efficiency improved to 7.15%. Despite the limitations of VSM in discontinuous flows, its use increased process efficiency, demonstrating its applicability in complex industrial contexts. Full article

This study addresses the issue of poor construction labor productivity, exploring the process and methodology for increasing construction workers’ participation in labor productivity improvement, as well as a situational awareness (SA) development approach for construction workers based on lean construction (LC). A framework for enhancing labor productivity through SA has been developed. A case study approach is utilized to describe the LC improvement process, which includes enhancing construction workers’ SA for waste minimization and process optimization and engaging them in LC with improved value stream mapping (VSM). The labor productivity measurement approach, combined with VSM, is used to evaluate the labor productivity improvement with labor productivity improvement rate, resource efficiency, and flow efficiency. The results demonstrate that the labor productivity of the case project has increased by 24.07%, with 11.54% contributing resource efficiency and 88.46% contributing flow efficiency, indicating a greater increase in flow efficiency. This study fills a research gap in terms of the combination of construction workers’ SA enhancement and the involvement of LC practices to boost labor productivity. Furthermore, this study proposes an SA development approach based on LC at three levels: waste perception, VSM implementation, and labor productivity improvement assessment. This provides new perspectives for leveraging construction workers’ SA to increase labor productivity. The improved VSM approach and labor productivity measurements provide an operationalization of workers’ participation in continuous improvement. This research is of great practical relevance for augmenting the competencies of construction laborers and inspiring them to engage in labor productivity enhancement. Full article

The construction industry is adopting a collaborative paradigm by combining Lean construction (LC) principles and BIM capabilities. Existing studies lack sufficient case studies and performance evaluations, especially for the disassembly and reconstruction stage, creating a gap in the practical application of BIM and Lean construction (BIM-LC) in China. To bridge this gap, this study quantitatively assessed the BIM-LC methodology in a relocation project in Dezhou, China. The project employed BIM-LC practices such as the Last-Planner System (LPS), Just-In-Time (JIT), Kanban, Value-Stream Mapping (VSM), and Continuous Improvement to enhance construction efficiency and minimize waste. Two main areas of the relocation process were investigated: (i) the identification of common barriers and on-site solutions to the implementation of BIM-LC; (ii) evaluation of the construction efficiency, construction and demolition waste (CDW), and carbon-emission performance. The results showed that the BIM-LC strategy improved labor efficiency and productivity by 3.4% and 12.9%, shortened the construction period by 11 days, reduced construction costs by 8.07% (i.e., USD 9093.8), and reduced transportation costs by 12.5% (i.e., USD 1875). The CDW generation rate ranged from 1–5%, which is comparable to the rates observed in residential construction across various countries. The total weight was 1903.8 kg (10.4 kg/m²). Moreover, the carbon emission during the relocation process was 15,288.4 kgCO₂e, with a carbon intensity of 83.5 kg/m². This study extends the knowledge systems on the application of the BIM-LC method in relocation projects and supports data-driven decision making. It also plays a crucial role in fostering new markets for recycled components, contributing to the realization of a sustainable built environment. Full article

The Integral Ergonomic-Value Stream Mapping (Ergo-VSM) methodology is introduced in this study, which is tailored for the metal-mechanic sector and aims to assess the operational and ergonomic conditions of production processes. The methodology is designed to identify ergonomic risks and propose an improvement plan to increase productivity by integrating ergonomic measurement instruments aligned with official standards and lean manufacturing tools such as VSM and Kaizen. The study, which was conducted in a metal-mechanical MSME (micro, small and medium enterprises), resulted in an 11.8% overall improvement in psychosocial risk factors, a 4.4% increase in productivity with a 1.96-h reduction in cycle time, and a 20% decrease in reported quality rejections. Notably, the study shows that the Integral Ergo-VSM can be implemented in a variety of organizational contexts, ensuring adaptability without jeopardizing the methodology’s core objectives. Full article

Manufacturing companies strive to minimize costs, maximize efficiency and improve production quality, which is crucial for market competitiveness. As companies grow and technologies evolve, increasingly complex challenges arise in effectively managing and improving production processes. One of the tools that helps companies improve their processes is value-stream mapping (VSM). The article focuses on the use of VSM in the production process of hand tools used in the construction industry. The paper presents selected aspects of the optimization of the production process using the mapping concept. The research identified and characterized the most important processes occurring in the production of hand tools used in construction. Then, basic data on the value stream was collected and the need for improvements and actions aimed at optimizing the value stream was indicated. Financial results, key performance indicators (KPIs), machine operation and reliability, energy consumption in the production process and overall equipment effectiveness (OEE) before and after improvements were calculated. The analysis carried out allowed for the optimization of the production process in terms of economy and energy consumption. As a result of the improvements, the productivity of injection-molding workers increased by 9.4% and the overall equipment efficiency by 18%. The machine availability rate increased from 70.3% to 85.2%. After implementing the improvements, the company is able to save approximately 295,488 kWh annually, i.e., approximately EUR 53,253, while 1 kWh currently costs producers in Poland EUR 0.18. The conclusions and results described in the paper constitute a solid basis for further development of an improvement project for the selected company. Full article

The implementation of lean manufacturing to increase productivity often neglects the impact on the environment and the well-being of employees. This can result in negative consequences such as environmental harm and poor employee satisfaction. To address this issue, an integrated ergo-green-lean conceptual model was developed in the literature. However, no case study has been conducted to support this model. Therefore, this research aims to investigate the practical outcomes of implementing the integrated framework in an automobile parts industry. Key performance indicators (KPIs) were identified, including ergonomic risk score, job satisfaction, carbon footprint emission both from direct energy consumption and material wastage, cycle time, lead time, die setup time, and rejection rate. Various assessment techniques were employed, such as the rapid entire body assessment (REBA) with the Standard Nordic Questionnaire (SNQ), job stress survey, carbon footprint analysis (CFA), and value stream mapping (VSM) to evaluate the KPIs at the pre- and post-intervention phases. The results demonstrate significant improvements in job satisfaction (49%), improved REBA score of 10 postures with very high risk numbers by 100%, a 30.3% and 19.2% decrease in carbon emissions from energy consumption and material wastage, respectively, a 45% decrease in rejection rate at the customer end, a 32.5% decrease in in-house rejection rate, a 15.5% decrease in cycle time, a 34.9% decrease in lead time, and a 21% decrease in die setup time. A Python regression model utilizing sklearn, pandas, and numpy was created to assess the relationship between process improvement and the chosen KPIs. Full article

Background: Nowadays, as a result of globalization, markets are more competitive, and customers are more demanding. To respond to these challenges, organizations must develop mechanisms for continuous improvement in order to eliminate waste and increase the efficiency and effectiveness of processes. Thus, the present study carried out at an industrial unit responsible for the customization of cork stoppers for wines had as its main objectives to identify and eliminate or at least reduce waste; improve production and internal logistics flows; balance workloads; improve productivity; reduce lead time; motivate employees and promote the spirit of continuous improvement. Methods: The action-research methodology was used, whereby several cycles of data recovery and analysis, identification and implementation of opportunities for improvement, assessment and standardization were carried out. Therefore, the Total Flow Management (TFM) model was implemented, and several methods and tools were used, such as Value Stream Mapping (VSM), work measurement and 5S’s. Results: Several wastes and overloads were identified, and some actions were implemented, such as workload balancing, layout changes, implementation of visual management and supermarkets. That said, it was possible to reduce lead time by 4 days, improve productivity from 26.63 ML (a thousand cork stoppers)/h to 35.75 ML/h, and promote flexibility. In addition, employees were motivated, and a culture of continuous improvement was fostered. Conclusions: This project demonstrated that it is possible to implement improvement actions, with good results, without high investments, as well as motivating employees and taking advantage of their best capabilities. Additionally, it was demonstrated that the use of TFM can be very useful in continuous improvement, with evident improvements in production and internal logistics flows. So, this project demonstrated the practical implementation of TFM regarding basic reliability, production and internal logistics flow, and the simultaneous use of several methods and tools to implement continuous improvement. Thus, significant improvements were possible on the factory floor, as well as improving employee motivation their personal development and encouraging the focus on continuous improvement. Therefore, it responds to the gap identified in the literature. Full article

This study aims to improve the assembly manufacturing process to solve the workload imbalances by combining value stream mapping (VSM) and ranked positional weight (RPW). An empirical study was conducted in a defense manufacturing firm located in Indonesia. The study specifically focused on 155 components and 56 tasks distributed among 43 assembly workstations in one weapon product. The results of the analysis showed a significant reduction in the total cycle time, from 5121 s (85.35 min) to 3620 s (60.33 min), or a decrease of 29%. Additionally, the study found improvements in the balance of the assembly line as measured by balance delay, line efficiency, and smoothness index performance indicators. The application of VSM and RPW in this study is unique in the context of the defense industry, as it provides empirical analysis on cycle time and assembly line balance, which is rarely studied. The results of this study contribute to the advancement of literature in the field and provide valuable insights for other organizations in the defense industry and other manufacturing industries. By improving the efficiency and balance of the weapon assembly line, this study has the potential to increase productivity and reduce waste. Full article