Design of lean manufacturing systems using value stream mapping with simulation

Gurumurthy, Anand; Kodali, Rambabu

doi:10.1108/17410381111126409

Cited by 152 publications

(86 citation statements)

References 53 publications

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“…According to Gurumurthy and Kodali (2011), this is because lean has been more widely applied in the manufacturing industry and therefore more recorded research is available in this sector. Examples of reported applications of VSM in the manufacturing industry are presented in Table 1.…”

Section: The Concept Of 'Value' and Vsmmentioning

confidence: 99%

“…A common element in all the studies presented in Table 1 is the fact that VSM has been predominantly applied for productivity improvement in all these organisations. Gurumurthy and Kodali (2011) comment that although VSM has been traditionally used for productivity improvements, in recent times it has also been applied for other purposes such as improving leadership, perform benchmarking, and increase value across the supply chain. Rajenthirakumar and Thyla (2011) Similarly as with the application of lean manufacturing, although the academic literature shows some evidence of the use of VSM in the Indian manufacturing industry, it also indicates that organisations in this country have given preference to the use of other lean tools such as kaizen, Total Productive Maintenance, and 5S (Vinodh et al, 2010;Garza-Reyes et al, 2012).…”

Section: The Concept Of 'Value' and Vsmmentioning

confidence: 99%

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A VSM improvement-based approach for lean operations in an Indian manufacturing SME

Saboo¹,

Reyes²,

Er³

et al. 2014

IJLER

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Abstract:The current economic environment in the Indian manufacturing industry is offering a perfect opportunity to SMEs of this country to develop and grow by acting as suppliers of large multinational original equipment manufacturers (OEMs). To meet the challenge of offering high standards of quality, cost and delivery (QCD) to these multinational OEMs, Indian manufacturing SMEs must implement effective approaches, such as lean manufacturing, to continually and systematically improve their operations. However, the academic literature indicates that the adoption of lean manufacturing and some of its tools, such as value stream mapping (VSM), by Indian manufacturing SMEs is feeble, or in many cases lean initiatives have been unsuccessful. This paper presents a successful application of VSM in an Indian manufacturing SME. The results of the study and operational improvements achieved indicate that the application of VSM is an effective 42 A. Saboo et al.strategy for organisations of this type to improve their processes and thus meet their current challenges. This paper contributes by providing empirical evidence of the application of VSM in India and thus it can be used as a guiding reference for managers and engineers to undertake specific process improvement projects, in their organisations, similar to the one presented in this paper.Keywords: India; lean operations; manufacturing; SME; value stream mapping; VSM.Reference to this paper should be made as follows: Saboo, A., Garza-Reyes, J.A., Er, A. and Kumar, V. (2014) 'A VSM improvement-based approach for lean operations in an Indian manufacturing SME', Int.

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Section: The Concept Of 'Value' and Vsmmentioning

confidence: 99%

Section: The Concept Of 'Value' and Vsmmentioning

confidence: 99%

A VSM improvement-based approach for lean operations in an Indian manufacturing SME

Saboo¹,

Reyes²,

Er³

et al. 2014

IJLER

View full text Add to dashboard Cite

show abstract

“…This solution to evaluate the profitability of an investment, that constitutes a base requirement for the financing of lean introduction (Sullivan, McDonald & van Aken, 2002), is usually cost effective and generally cheaper than a practical on the field test. Many examples of this approach combining VSM and simulations are available in literature (Abdulmalek & Rajgopal, 2007;Bernards, van Engelen, Schrauwen, Cramer & Luitjens, 1990;Gurumurthy & Kodali, 2011;Lian & van Landeghem, 2007;McDonald et al, 2002;Narasimhan, Parthasarathy & Narayan, 2007;Wang, Guinet, Belaidi & Besombes, 2009). One of the most popular simulation tools available on the internet is Arena Simulation (Detty & Yingling, 2000;Hammann & Markovitch, 1995;Kelton, 2002).…”

Section: Simulation As Support To Value Stream Mappingmentioning

confidence: 99%

Exploring the impact of Lean manufacturing on flexibility in SMEs

Lucherini

Rapaccini

2017

JIEM

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Abstract:Purpose: This paper describes the use of simulation and case-study research to assess flexibility gains induced by the adoption of three Lean Manufacturing practices.Design/methodology/approach: We gather useful material and information about the manufacturing process of a selected Small-Medium Enterprise by adopting a case-research approach. The Value Stream Mapping is the method used for visualizing flows of products and information along the production system. Starting from the current arrangement of the company, computer simulation is used to assess the benefits arising from Cellular Manufacturing, Just-in-Time Delivery by Suppliers, and Single Minute Exchange of Dies. Findings: To investigate the flexibility improvements coming from the introduction of LeanManufacturing, we present a simulation model of the described company on which we performed our analysis. We quantify the flexibility of different configurations according to the new 5-step approach in order to segregate the contribution of different lean techniques. Originality/value:We extend the combined use of Case Research and Computer Simulation to the research on Manufacturing Flexibility within Small-Medium Enterprises. We enhance the knowledge on this under investigated context collecting quantitative field data. Moreover, building on the factorial Design of Experiment, we introduce a new 5-step method to appraise the costbenefit ratio of lean techniques for flexibility. The managerial implication of this research is -919-Journal of Industrial Engineering and Management -https://doi.org/10.3926/jiem.2119 mostly related to the provision of a supporting method for the decision making process propaedeutic to Lean Manufacturing introduction.

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“…Gurumurthy and Kodali [10] emphasised in their study that traditional VSM cannot be used for maintenance activities. Thus they developed a VSM specifically for maintenance in order to evaluate the non-value-adding (NVA) activities.…”

Section: Introductionmentioning

confidence: 99%

A Stochastic Analysis Approach on the Cost-Time Profile for Selecting the Best Future State Ma

Seyedhosseini

Ebrahimi

2015

The South African Journal of Industrial Engineering

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In the literature on value stream mapping (VSM), the only basis for choosing the best future state map (FSM) among the proposed alternatives is the time factor. As a result, the FSM is selected as the best option because it has the least amount of total production lead time (TPLT). In this paper, the cost factor is considered in the FSM selection process, in addition to the time factor. Thus, for each of the proposed FSMs, the cost-time profile (CTP) is used. Two factors that are of particular importance for the customer and the manufacturer -the TPLT and the direct cost of the product -are reviewed and analysed by calculating the subarea of the CTP curve, called the cost-time investment (CTI). In addition, variability in the generated data has been studied in each of the CTPs in order to choose the best FSM more precisely and accurately. Based on a proposed step-by-step stochastic analysis method, and also by using non-parametric Kernel estimation methods for estimating the probability density function of CTIs, the process of choosing the best FSM has been carried out, based not only on the minimum expected CTI, but also on the minimum expected variability amount in CTIs among proposed alternatives. By implementing this method during the process of choosing the best FSM, the manufacturing organisations will consider both the cost factor and the variability in the generated data, in addition to the time factor. Accordingly, the decision-making process proceeds more easily and logically than do traditional methods. Finally, to describe the effectiveness and applicability of the proposed method in this paper, it is applied to a case study on an industrial parts manufacturing company in Iran. OPSOMMINGVolgens die literatuur oor waarde stroom kartering (VSM) is die tydfaktor die enigste rede vir die kies van die beste eienskap toestand kaart (FSM) bo die ander voorgestelde alternatiewe. FSM word gekies as die beste opsie omdat dit die kortste totale produksie lei tyd het. Hierdie artikel oorweeg die kostefaktor in die FSM seleksie proses saam met die tydfaktor. Dus, vir elkeen van die voorgestelde FSM kaarte word die koste-tyd profiel gebruik. Twee faktore wat van uiterste belang vir die kliënt en vervaardiger is, naamlik die totale produk lei tyd en die direkte koste van die produk, is hersien en analiseer deur die area onder die koste-tyd profiel kurwe te bereken. Hierdie area staan bekend as die kostetyd belegging. Verder word veranderlikheid in die gegenereerde data bestudeer in elk van die koste-tyd profiele, sodat die beste FSM meer presies gekies kan word. Die beste FSM is bepaal deur 'n voorgestelde treë-vir-treë stogastiese analise metode en 'n nie-parametriese Kernel skatting van die waarskynlikheiddigtheidfunksie van die koste-tyd belegging. Die seleksie van die beste FSM is dus nie net op die minimum verwagte koste-tyd belegging gekies nie, maar ook op die minimum verwagte veranderlikheid van die koste-tyd belegging. Deur hierdie metode van FSM seleksie sal fabrikante beide die koste faktor en di...

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Design of lean manufacturing systems using value stream mapping with simulation

Cited by 152 publications

References 53 publications

A VSM improvement-based approach for lean operations in an Indian manufacturing SME

A VSM improvement-based approach for lean operations in an Indian manufacturing SME

Exploring the impact of Lean manufacturing on flexibility in SMEs

A Stochastic Analysis Approach on the Cost-Time Profile for Selecting the Best Future State Ma

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