Deployment of fuzzy TOPSIS-integrated value stream mapping for a fabrication industry: a case study

Abstract

PurposeThis research aims to identify lean tools and techniques that are needed to be implemented to improve the performance in the fabrication industry. The objective is to find the wastes in manufacturing processes using value stream mapping (VSM) and prioritize the lean tools suitable to enable the attainment of leanness and streamline the processes.Design/methodology/approachVSM tool is applied in the industry to construct the current state map, identify improvement proposals and implement in future state. Fuzzy technique for order performance by similarity to ideal solution (TOPSIS), a multi-criteria decision-making technique (MCDM), is used to prioritize the identified improvement proposals. This study observed that mistake-proof processing and layout organization are the two techniques with the top priority that needs further improvement to enhance the leanness of the organization.FindingsUpon successful implementation, the cycle time is reduced by 14.97%, and total inventory is reduced by 45.67% which leads to the improvement of value addition from 5.88 to 9.21%. Although lean has been adopted for many years, implementation of lean in the fabrication industry has been limited.Practical implicationsThis study addresses the challenges in terms of implementing lean in fabrication industries and practical implications of lean tools and techniques and the prioritization of lean concepts against various lean criteria to enable leanness.Originality/valueThe deployment of improvement prioritization tool integrated with VSM in the context of a fabrication industry is the original contribution of the authors.

Implementation of lean manufacturing methods to improve rolling mill productivity

“…[48] also, state that the education and training aspect of TPM is extremely important in increasing industrial productivity. Implementation of SMED and TPM methodologies has definitely improved machine availability and performance [25,[49][50][51]. Mofolasayo et al [17] confirmed that lean methodology helps in increasing productivity by reducing waste.…”

“…Many researchers applied TPM and SMED methods to improve productivity. Aadithya et al [25] implemented TPM and SMED methods in an equipment manufacturing company. Their objective was to identify the factors that hinder the production process and found that the company facing significant challenges, such as insufficient stock in feed and long equipment turnaround times.…”

“…The ultimate goals of TPM include zero breakdowns, zero defects, zero machine stoppages, zero accidents, and zero pollution. By measuring and comparing these metrics, organizations can strive for continuous improvement and operational excellence [25].…”