Abstract. Lean Manufacturing concept is well described in the literature in the context of low-mix high-volume production. There are numerous case studies proving outstanding benefits of implementation Lean principles. Nowadays enterprises have to face the problem of high variety of products and dynamically changing demand. Lean tools and methods known from repetitive production do not always fit to high-mix environment. It causes problems with proper design of one-piece-flow production cells and material flow based on pull system.
The paper presents the problems with integration of the companies within the supply chain. Usually the separate actions are undertaken by the companies to implement lean tools for production systems and external logistics processes. This situation leads to minor results or moving the costs between production and logistics processes instead of reduction. The purpose of the paper is to present the new version of Value Stream Mapping method, focused on synchronised reorganisation of company production system, external logistics processes between the company and its suppliers as well as suppliers' production processes. This paper shows the techniques currently used to support cooperation between enterprises and will demonstrate their incompleteness and how they can be improved.
This paper is based on the findings from the project funded by the Ministry of Science and Higher Education of Poland. It presents the application of value stream mapping in supply chains and some inadequacy of this method for supply chain integration. Based on the findings, a new Supplier Customer Production process Integration SCPI methodology is proposed. The paper presents problems with integration of companies within the lean supply chain. Usually separate actions are undertaken by the companies within the same supply chain to implement lean management philosophy for production systems and external logistics processes. These isolated activities may lead to pushing inventories from one supply chain partner to another instead of reducing them. To reduce inventories along the supply chain the new approach of production and logistics process improvement needs to be applied. The new concept must take into consideration influence of local improvements in one plant on other cooperating enterprises as well as on the logistics system between them.
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