Development of sustainable value stream mapping (SVSM) for unit part manufacturing: A simulation approach
International Journal of Lean Six Sigma
ISSN: 2040-4166
Article publication date: 30 September 2019
Issue publication date: 14 May 2020
Abstract
Purpose
The main purpose of this paper is to analyze the current state of a bonnet-manufacturing industry and to optimize the process by designing a future state map using simulation approach.
Design/methodology/approach
The case study approach has been proposed to highlight the applicability of value stream mapping (VSM) in an Indian bonnet manufacturing organization. The methodology used relies on formulation of VSM being the main tool used to identify the opportunities for classifying and eliminating bottlenecks with the help of various lean techniques. A contrast of present and past scenarios is highlighted to underscore the importance of using VSM with ARENA simulation.
Findings
Application of the proposed simulation approach has helped the organization reduce the cycle time significantly by 30 per cent over the entire production time. The average number of work-in-progress pieces has also decreased by about ten. In addition, enhancements have been seen with respect to ecological parameters, e.g. carbon footprint has been reduced to 83.7 percent across the process.
Research limitations/implications
The proposed approach of using a simulation-based VSM helps in reducing the time involved in traditional VSM method. This approach is also easy to implement at any organizational level.
Practical implications
It is believed that this paper will aid not just industrialists but also academic professionals to appreciate the role of simulation using ARENA in helping them understand how to attack the various problems faced by industries. The results of the study indicate that by applying this methodology, there will be a reduction not only in cost but also in environmental impacts.
Originality/value
The paper incorporates a real case study, which shows application of VSM for implementing lean principles in a bonnet-manufacturing industry. Break-even analysis presented fills the gap which previous literatures have been missing.
Keywords
Acknowledgements
The authors are grateful to the referees and the editor. Their comments and suggestions have improved the content and readability of the paper.
Declaration of conflicting interests: The authors declare no potential conflicts of interest with respect to the research, authorship and/or publication of this article.
Funding: The authors did not receive financial support for the research, authorship and/or publication of this article.
Citation
Mishra, A.K., Sharma, A., Sachdeo, M. and K., J. (2020), "Development of sustainable value stream mapping (SVSM) for unit part manufacturing: A simulation approach", International Journal of Lean Six Sigma, Vol. 11 No. 3, pp. 493-514. https://doi.org/10.1108/IJLSS-04-2018-0036
Publisher
:Emerald Publishing Limited
Copyright © 2019, Emerald Publishing Limited