Applying value stream mapping in an unbalanced production line: A case study of a Chinese food processing enterprise

Liu, Qingqi; Yang, Haojin; Xin, Yuchen

doi:10.1080/08982112.2019.1637526

Cited by 15 publications

(8 citation statements)

References 41 publications

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“…Lean manufacturing is famous for production system improvements, but it is difficult for dynamic processes where visibility is critical. Simulation is a complementary tool for the difficulties of production process dynamics [21]. Evaluating the environmental impact in a dynamic production process needs more visibility to sup-port decision-making.…”

Section: Literature Reviewmentioning

confidence: 99%

Productivity Improvement using Simulated Value Stream Mapping: A Case Study of the Truck Manufacturing Industry

Poswa¹,

Mpofu²,

Adenuga³

2022

Preprint

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The accumulation of process waste in the production line causes fluctuations, bottlenecks, and increased inventory in workstations disrupting process flow. In this paper, the aim is the use a simulated value stream mapping (SVSM) as a lean assessment tool for decision-making in the continuous improvement process to influence and provide consideration and consistency on productivity improvement in the production system. The proposed methodology applied discrete event simulation for production process operations improvement to eliminate non-value adding times and provides good quality products at the lowest cost and highest efficiency. The results are the analysis of the current state of the production system in a South African truck manufacturing industry small and medium enterprise (SMEs) as a potential solution for the production system future state. The identified non-value adding times in the 6 most critical workstations was eliminated by SVSM which resulted in a productivity improvement of 4%, most importantly bringing the productivity to 95% and total cycle time improvement to 451 for small units and 466 for large units. The results proposed combined VSM and Simulation techniques which enhance the LEAN application by DES to increase productivity and performance improvement to remain competitive in the global economy.

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Section: Literature Reviewmentioning

confidence: 99%

Productivity Improvement using Simulated Value Stream Mapping: A Case Study of the Truck Manufacturing Industry

Poswa¹,

Mpofu²,

Adenuga³

2022

Preprint

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“…It is a management method for companies that try to adapt to current market conditions by way of functional and organizational changes (Dekier, 2012). Lean management also results in reducing costs, increasing customer interactions, quality, enhanced employee morale and improvements in culture and the use of push and pull systems (Liu, Yang, & Xin, 2019).…”

Section: Lean Management In the Food Industrymentioning

confidence: 99%

“…Lean management in the food industry is essential since the industry is a changeable sector (Singh, Luthra, Mangla, & Uniyal, 2019), in which production batches and processing times at the production stages vary because of seasonality and the shortness of shelf-life factors (Dora et al, 2014;Liu et al, 2019). In contrast with other industries, many food and agricultural products are harvested at certain times of the year and must be processed in large batches regardless of the frequency of customer demand (Liu et al, 2019;Mahalik & Nambiar, 2010). Therefore, it is difficult to produce on time within this sector.…”

Section: Lean Management In the Food Industrymentioning

confidence: 99%

Reducing Food Waste Through Lean and Sustainable Operations: A Case Study From the Poultry Industry

et al. 2021

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The growing need for solving the problem of food waste for tackling the survival of the planet and humankind is encouraging researchers to seek sustainable operations that alter the conventional methods that are currently in use in the food industry. Lean thinking has been used in this study to propose sustainable operations that incorporate social, economic, and environmental aspects and to handle the multidisciplinary and complex nature of reducing food waste. The value stream mapping methodology has been employed to explain food waste and generate drivers and to observe the end-to-end system flow. Since most of the waste is observed in upstream operations in emerging economies, one of the biggest meat-processing companies in Turkey is studied for illustrating the proposed methodology. As a result of the model, lean and sustainable food operations are suggested considering social, economic and environmental aspects.

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“…Mainstream studies tend to focus on organizations that have less than 10 years' experience of implementing Lean, and which operate in a mass production environment such as the automotive and related sectors (Apafaian et al., 2020), electronics (Jayanth et al., 2020; Wong & Wong, 2011), food (Liu et al., 2020), and textiles (Mahmood, 2020; Wickramasinghe & Wickramasinghe, 2017). In contrast, this study looks at a different type of production environment: job shop production.…”

Section: Introductionmentioning

confidence: 99%

Exploring the factors that hinder Lean improvement initiatives in a job shop environment: A qualitative case study of a Malaysian company

Samad

Othman

2022

Glob Bus Org Exc

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Job shop production faces various challenges regarding the use of lean manufacturing (Lean) initiatives to sustain a competitive advantage; losing the ability to maintain continual improvement of longstanding initiatives is one of the most significant. This study explores how Lean improvement initiatives can be affected by years of indifferent treatment. Consisting of a single qualitative case study conducted in a Malaysian company that has implemented Lean initiatives for more than 20 years, our findings reveal that Lean implementations in job shop environments can deteriorate over time. Our analysis identifies three overarching themes. First, even though the company has many years' experience of lean implementation, a lack of organizational engagement hindered further improvements. Second, the resource capabilities provided, became outdated, and in poor condition. Third, the company saw a rapidly diminishing level of commitment among its workers. Thus, although the company had previously enjoyed some success in implementing Lean, its ability to keep the momentum behind its initiatives began to fade. The study will help guide practitioner's actions when implementing Lean initiatives, and will enhance the knowledge of issues related to long term Lean implementations in job shop production.

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Applying value stream mapping in an unbalanced production line: A case study of a Chinese food processing enterprise

Cited by 15 publications

References 41 publications

Productivity Improvement using Simulated Value Stream Mapping: A Case Study of the Truck Manufacturing Industry

Productivity Improvement using Simulated Value Stream Mapping: A Case Study of the Truck Manufacturing Industry

Reducing Food Waste Through Lean and Sustainable Operations: A Case Study From the Poultry Industry

Exploring the factors that hinder Lean improvement initiatives in a job shop environment: A qualitative case study of a Malaysian company

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