Value stream mapping approach and analytical network process to identify and prioritize production system’s Mudas (case study: natural fibre clothing manufacturing company)

Behnam, Donya; Ayough, Ashkan; Mirghaderi, Seyed Hadi

doi:10.1080/00405000.2017.1322737

Cited by 27 publications

(14 citation statements)

References 13 publications

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“…The authors agree that small and medium-sized enterprises (SMEs) are often under pressure owing to a difficult financial situation and must increase effectiveness to maintain their competitive advantage. Thus, they argued that Lean tool implementation is the best method to address the supply chain management and the industry's production environment to improve its productivity [12][13] [14]. They implemented the five principles that define the Lean concept: (1) defining value, (2) mapping the value stream, (3) creating flow, (4) using a pull system, and (5) pursuing perfection, in addition to the definition of waste and the increase in production and efficiency.…”

Section: B Lean Manufacturing Applied To Waste Reduction Models In Tmentioning

confidence: 99%

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Lean Manufacturing Model of Waste Reduction Using Standardized Work to Reduce the Defect Rate in Textile MSEs

Tapia-Cayetano¹,

Barrientos-Ramos²,

Maradiegue-Tuesta³

et al. 2020

Proceedings of the 18th LACCEI International Multi-Conference for Engineering, Education, and Technology: Engineering, Integrat

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The textile industry currently represents 7.2% of the manufacturing companies' GDP. However, it has experienced severe sales volatility owing to the high competitiveness, primarily mainly from Southeast Asian countries. Low productivity, process variability, operating cost overruns or long lead times are the main causes of the sector gap that must be attacked. Thus, this research is aims to contribute to the textile industry with methodologies and tools to gain a competitive advantage and reduce its operating cost overruns. We analyzed a real case study applied to a company called TEXTIL S.AC., following the implementation of combined work to integrate labor, work method, and machines to reduce the manufacturing cycle time by 300 seconds and, thus, waste such as defective products that generate expenses for the company. The results of the implementation and validation through process simulation showed an 8% reduction in the defect rate and a 32% improvement in the lead times.

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Section: B Lean Manufacturing Applied To Waste Reduction Models In Tmentioning

confidence: 99%

“…[9][10] [11]. In general terms, one of the main benefits and results of Lean tool implementation in the textile industry are the improvement in production line efficiency, inventory reduction, improved production process, reduction of defective products, and equipment performance [14] [15].…”

Section: B Lean Manufacturing Applied To Waste Reduction Models In Tmentioning

confidence: 99%

Lean Manufacturing Model of Waste Reduction Using Standardized Work to Reduce the Defect Rate in Textile MSEs

Tapia-Cayetano¹,

Barrientos-Ramos²,

Maradiegue-Tuesta³

et al. 2020

Proceedings of the 18th LACCEI International Multi-Conference for Engineering, Education, and Technology: Engineering, Integrat

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“…VSM method was used for waste assessment, the AHP method was introduced for weighting and ranking the evaluated wastes. Behnam et al (2018) proposed an integrated approach using VSM and ANP methods. VSM is used to identify the different kinds of wastes.…”

Section: Literature Reviewmentioning

confidence: 99%

Enhancement of value stream mapping application process through using fuzzy DEMATEL and fuzzy QFD approaches: a case study considering economic and environmental perspectives

Aouag

Soltani

Mouss

2020

JM2

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Purpose This paper aims to investigate an integrated approach that aims at enhancing the application process of value stream mapping (VSM) method. It also proposes an extended VSM called Economic and Environmental VSM(E-EVSM). The proposed approach highlights the improvement of economic and environmental performances. Design/methodology/approach The proposed approach has studied the integration of VSM, fuzzy decision-making trial and evaluation laboratory (DEMATEL) and fuzzy quality function deployment (QFD) to improve the economic and environmental performances of manufacturing processes. The VSM method is used for data collection and manufacturing process assessment, whereas fuzzy DEMATEL is used to analyse the current state map. Finally, fuzzy QFD is used to organize the improvement phase of VSM method. Findings The clear findings of this research prove the effectiveness of VSM method on the environmental and economic performances of manufacturing processes. In addition, the proposed approach will show the advantages of fuzzy DEMATEL and fuzzy QFD approaches in improving the application of the VSM method. Research limitations/implications The limitation of this study includes the lack of consideration of other dimensions such as social, technological and managerial. In addition, the proposed approach studied an average set of environmental and economic indicators. Originality/value The novelty of the proposed approach is proved by the development of an extended VSM method (E-EVSM). Also, the proposed approach contributes by a new methodology for analysing and improving the current state map of manufacturing processes.

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“…As a consequence, by characterizing the realized benefits from the plotted future state map, the author proposed to adopt the cellular layout structure, keizan and single piece flow principles as the remedial policies. Whereas, Behnam, Ayough and Mirghaderi [18] used the VSM to identify the Mudas in the manufacturing flow line of a natural fibre clothing industry and suggested to reduce the batch size, increase the workers, ensure the continuous flow and change the sequence of operations as the key policies for waste reduction. The VSM is also incorporated to identify the wastes of Textile shop floor by Carvalho, Carvalho & Silva [19].…”

Section: Introductionmentioning

confidence: 99%

Improvement of Operational Performance through Value Stream Mapping and Yamazumi Chart: A case of Bangladeshi RMG Industry

Kays*,

Prodhan,

Karia*

et al. 2019

IJRTE

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To secure a competitive position in the global market, the Ready Made Garment (RMG) sector in Bangladesh has been facing various challenges including the improvement of industrial operational performance. Among the various operational issues, balancing the cycle time along the production line is felt to be a common and effective way for enhanced performance. There are numerous exact and approximate methods which have already been proposed and are available in literature for repetitive batch production. Unfortunately such approaches are rarely applied in the real RMG shop floor presumably due to the enormous efforts needed to align with the frequent changes of product lines. Compared to the exact and approximate methods, adoption of lean tools like VSM and Yamazumi chart is highly acclaimed for their simpler and wider applicability with superior capability in addressing and solving the balancing problems. So for balancing purposes of the RMG shop floor an attempt is made to frame and apply an integrated model combining the VSM and Yamazumi chart as presented in this article. Depending on the theoretical framework, operational performance of an RMG shop floor is evaluated upon balancing the cycle time. In doing so, firstly a current state map (CSM) and the corresponding Yamazumi chart are plotted to comprehend the existing operational procedure and analyse the workstation cycle time with respect to the takt time. Using the Yamazumi chart, the workstations are reorganized to reduce or eliminate the non-value added activities, to introduce parallel workstations, and to merge workstations so that a balanced production line is attained. Performance is then assessed by means of Overall Effectiveness of Equipment (OEE), Capacity Utilization and Efficiency. The results as obtained through testing a real life case study of RMG industry, ensure the effectiveness of the integrated system of VSM and Yamazumi chart to identify the wastes, restore the line balance and improve operational performance.

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Value stream mapping approach and analytical network process to identify and prioritize production system’s Mudas (case study: natural fibre clothing manufacturing company)

Cited by 27 publications

References 13 publications

Lean Manufacturing Model of Waste Reduction Using Standardized Work to Reduce the Defect Rate in Textile MSEs

Lean Manufacturing Model of Waste Reduction Using Standardized Work to Reduce the Defect Rate in Textile MSEs

Enhancement of value stream mapping application process through using fuzzy DEMATEL and fuzzy QFD approaches: a case study considering economic and environmental perspectives

Improvement of Operational Performance through Value Stream Mapping and Yamazumi Chart: A case of Bangladeshi RMG Industry

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