Simulation guided value stream mapping and lean improvement: A case study of a tubular machining facility
Abstract: This paper describes
a typical Value stream mapping (VSM) application enhanced by the discrete event
simulation (DES) to a dedicated tubular manufacturing process.
Design/Methodology/Approach: VSM is prescribed as part of lean production
portfolio of tools, not only highlights process inefficiencies, transactional
and communication mismatches, but also guides improvement areas. Meanwhile, DES
is used to reduce uncertainty and create consensus by visualizing dynamic
process views. It is served as a complementary tool for the traditional VSM to
provide sufficient justification and quantifiable evidence needed to convince
the lean approaches. A simulation model is developed to replicate the operation
of an existing system, and that of a proposed system that modifies the existing
design to incorporate lean manufacturing shop floor principles.
Findings: A comprehensive model for the tubular manufacturing process is
constructed, and distinctive scenarios are derived to uncover an optimal future
state of the process. Various simulation scenarios are developed. The simulated
results are acquired and investigated, and they are well matched with the real
production data.
Originality/Value: DES is demonstrated as a guided tool to assist
organizations with the decision to implement lean approaches by quantifying
benefits from applying the VSM. A roadmap is provided to illustrate how the VSM
is used to design a desired future state. The developed simulation scenarios
mimic the behavior of the actual manufacturing process in an intuitive manner.
Keywords: Value stream
mapping; Discrete event simulation; Capacity analysis; Layout modification;
Lean manufacturing; Tubular machining
Author: Wei Xia, Jiwen Sun
Journal Code: jptindustrigg130023
