Value Stream Mapping as a Supporting Management Tool to Identify the Flow of Industrial Waste: A Case Study

Abstract

The Value Stream Mapping (VSM) method was applied to a case study in the iron and steel industry in Southern Africa as a supporting management tool to identify, demonstrate, and evaluate industrial waste and comprised of three steps. The first step included collecting and verifying waste generation and flow data as the VSM data input step. The second step comprises three phases: mapping waste generation and fractions and horizontal and vertical performance analysis. The third step is comprised of actual and future state maps compilation. Following the first year of implementation, waste was reduced by 28%, and waste removal cost by 45%. Implementing the VSM method demonstrated cost savings and reduced waste flow within the study’s first year. The initial waste generation reduction target of 5% per annum was exceeded. The VSM method application proved to be a practical method for the iron and steel industry to visualize and analyze waste flows, identify opportunities and challenges in waste management operations, reduce waste, promote lean manufacturing, and achieve an environmentally responsible zero-waste environment.

An Innovative Agile Model of Smart Lean–Green Approach for Sustainability Enhancement in Industry 4.0

“…2021, 7, x FOR PEER REVIEW 10 of 21efficient management systems in uncertain conditions[22,26,27,33,34,40,42,49,53]. The uncertain conditions include variation in product specification, limitations of constraints, resource unavailability, continuous changes in guidelines, and unspecified profitability[30,32,34,48,51,52,72]. To overcome these problems, the authors of the present research article proposed a model to control operational performance in each production condition faced in industrial scenarios.…”

A Lean Manufacturing Progress Model and Implementation for SMEs in the Metal Products Industry

“…Previous studies show that value chain implementation and management [28]. VSM enables a constant flow of products and services to the customer example, firms have used VSM to identify waste and inefficiency in new pro velopment [30], healthcare services [31,32], sales processes [33], and environme tainability [34,35]. The use of VSM, as shown in Figure 1, can be divided into f (1) selection of a part family; (2) current state map (including the collection of define ideal state; (4) future state map; and (5) action plan [36].…”

Using Value Stream Mapping to Eliminate Waste: A Case Study of a Steel Pipe Manufacturer

“…In 1978, for the first time, Taiichi Ohno presented the classification of muda, i.e., wastes occurring in an enterprise [1][2][3][4]. VSM was created as a solution to indicate the areas of waste present in the company and help in the development of possible improvements in order to reduce and eliminate mud [5][6][7][8].…”

“…Increasingly, companies are opting for a "lean" approach as a countermeasure to waste elimination. Currently, the Value Stream Mapping (VSM) method enables continuity in the flow of information and materials in production processes [6][7][8]. Another important feature of a given tool is its versatility, thanks to which it finds its application in many areas where we deal with adding value, especially in the manufacturing industry [16][17][18][19].…”