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Article
Publication date: 4 April 2016

Manuel F. Suarez-Barraza, José-Á Miguel-Davila and C. Fabiola Vasquez-García

The issue of the supply chain has been given much attention in recent decades, both in the academic arena as well as in the business world. It has become so important that…

7230

Abstract

Purpose

The issue of the supply chain has been given much attention in recent decades, both in the academic arena as well as in the business world. It has become so important that organizations have begun to directly manage the supply chain, appointing specific managers to perform this function. New challenges now include a focus on supply to determine the right time and place for product delivery. Some authors indicate a close relationship between Total Quality Management and the supply chain regarding its philosophical and operational goals and perspectives. Lee (2004) goes even further by indicating that only organizations that devise agile, adaptable and aligned supply chains will be able to continue competing in today’s environment. Therefore, observing and measuring the supply chain at all times is critical for today’s organizations. The purpose of this paper is to describe the implementation of a tool called Supply Chain Value Stream Mapping (SCVSM) in order to thoroughly understand competitive priorities of volume and delivery (On-time Delivery (OTD)) for any supply chain in organizations.

Design/methodology/approach

An exploratory case study was conducted. Two manufacturing company which have been established in Mexico with a robust supply chain for at least 20 years, were selected. The paper chronicles the implementation of SCVSM in both case studies. Three methods were used to gather data: direct observation; documentary analysis and semi-structured interviews.

Findings

This paper proposes a new tool for operation management called SCVSM. Its development, refinement and applied in both case studies. The evidence shows that it is possible to apply the tool (SCVSM) to visualize the variables volume and OTD in supply chains. In consequence, this research has made a small empirical contribution to the theoretical field of supply chain quality management.

Research limitations/implications

This paper has the same limitations as all other case-study-based research, including analysis subjectivity and questionable generalization of findings. There may well also be a theoretical gap in the geographic region because the paper only analyzes two companies established in Mexico.

Practical implications

Derived to describe both case studies on how to apply the SCVSM tool it may prove to be of value to practitioners and managers involved in the field. Similarly, a section on managerial implications has also been included.

Originality/value

The study contributes to the limited existing literature on the Supply Chain Quality Management and subsequently disseminates this information in order to provide impetus, guidance and support toward increasing the development companies in an attempt to move the Mexico manufacturing sector toward world class manufacturing performance.

Details

International Journal of Quality & Reliability Management, vol. 33 no. 4
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 1 December 2005

David H. Taylor

To develop an innovative methodology to apply lean value chain improvement techniques to a complete supply chain for a food product from farm to consumer.

27618

Abstract

Purpose

To develop an innovative methodology to apply lean value chain improvement techniques to a complete supply chain for a food product from farm to consumer.

Design/methodology/approach

Action research based on a UK case study involving farmers, a food processor and a major retailer.

Findings

Value stream analysis (VCA) highlights significant opportunities to improve supply chain performance, profitability and relationships.

Research limitations/implications

Lean/VCA methodologies can be readily applied to the retail and processor elements of food chains. However, further research is required to apply the concepts to farm operations.

Practical implications

Subsequent to this research, VCA techniques have been increasingly adopted in UK agri‐food sectors including meat, dairy, cereals and horticulture.

Originality/value

Application of lean concepts and VCA in the agri‐food sector. Development of a multi‐echelon supply chain improvement methodology.

Details

International Journal of Physical Distribution & Logistics Management, vol. 35 no. 10
Type: Research Article
ISSN: 0960-0035

Keywords

Article
Publication date: 8 June 2020

Ahmed Abideen and Fazeeda Binti Mohamad

Lean implementation is vastly incorporated in core manufacturing processes; however, its applicability in the supply chain and service industry is still in its infancy. To acquire…

2732

Abstract

Purpose

Lean implementation is vastly incorporated in core manufacturing processes; however, its applicability in the supply chain and service industry is still in its infancy. To acquire performance excellence and thrive in the global competitive market, many firms are adopting newer methodologies. But, there is a stringent need for production simulation systems to analyze supply chains both inbound and outbound. The era of face validation is slowly disappearing. Lean tools and procedures that provide future state assumptions need advanced tools and techniques to measure, quantify, analyze and validate them. The purpose of this study is to enable dynamic quantification and visualization of the future state of a warehouse supply chain value stream map using discrete event simulation (DES) technique.

Design/methodology/approach

This study aimed to apply an integrated approach of the value stream mapping (VSM) and DES in a Malaysian pharmaceutical production warehouse. The main focus is diverted towards reducing the warehouse supply chain lead time by initially constructing a supply chain value stream map (both present state and future state) and integrating its data in a DES modelling and simulation software to dynamically visualize the changes in future state value stream map.

Findings

The DES simulation was able to mimic the future state lead time reductions successfully, which assists in better decision-making. Improvements were seen related to total lead time, process time, value and non-value-added percentage. Warehouse performance metrics such as receiving, put away and storage rates were substantially improved along with pallet processing time, worker and forklift throughput usage percentage. Detailed findings are clearly stated at the end of this paper.

Research limitations/implications

This study is limited to the warehouse environment and further additional process models and functional upgrades in the DES software systems are very much needed to directly visualize and quantify all the possible Lean assumptions such as radio frequency image identification/Andon (Jidoka), 5S, Kanban, Just-In-Time and Heijunka. However, DES has a leading edge in extracting dynamic characteristics out of a static VSM timeline and capture details on discrete events precisely by picturizing facility modification and lead time related to it.

Practical implications

This paper includes all the fundamental pharmaceutical warehouse supply chain processes and the simulations of the future state VSM in a real-life context by successfully reducing supply chain lead time and allowing managers in inculcating near-optimal decision-making, controlling and coordinating warehouse supply chain activities as a whole.

Social implications

This integrated approach of DES and VSM can involve managers and top management to support the adoption of anticipated changes. This study also has the potential to engage practitioners, researchers and decision-makers in the warehouse industry.

Originality/value

This study involves a powerful DES software package that can mimic the real situation as a virtual simulation and all the data and model building are based on a real warehouse scenario in the pharmaceutical industry.

Article
Publication date: 10 January 2020

Ahmed Zainul Abideen and Fazeeda Binti Mohamad

The purpose of this study is to apply value stream mapping (VSM) in Malaysian pharmaceutical production warehouse. A current and future state value stream map from the raw…

2779

Abstract

Purpose

The purpose of this study is to apply value stream mapping (VSM) in Malaysian pharmaceutical production warehouse. A current and future state value stream map from the raw material receiving end to the production unit was developed to find out waste and unwanted lead time. It was very much essential to cut down the supply chain lead time at the initial phase as the raw material unloading, sorting, temporary storage and dispatch to production were seen contributing to a huge lead time build-up.

Design/methodology/approach

The study was initiated with the selection of a product family, construction of the current state map, identification of various wastes and the development of future state map.

Findings

The expected outcomes of the study include the quantification of wastes, improvement in value-added percentage and lead time reduction.

Research limitations/implications

The study was carried out in a single pharmaceutical company. The results of the study are deployable and can be functional in similar production organizations. Contrary to common VSMs that capture core production processes, this study provides strong insights that shall help design lean supply chains, especially in the pharmaceutical domain. This paper has also addressed the viability of the lean in the pharmaceutical warehouse and the reduction in lead time to improve demand forecasting, marketing and sales.

Practical implications

The results of this study have indicated that a significant reduction in pharmaceutical warehouse supply chain lead time is possible as a result of the implementation of VSM from the supply chain’s perspective.

Social implications

The insights from this study help in understanding the pharmaceutical supply chain risks and their outcomes.

Originality/value

The paper reports a real-time study conducted in a warehouse of a pharmaceutical organization. Hence, the contributions are original.

Details

International Journal of Pharmaceutical and Healthcare Marketing, vol. 14 no. 1
Type: Research Article
ISSN: 1750-6123

Keywords

Article
Publication date: 1 January 1997

Peter Hines and Nick Rich

Develops a new value stream or supplychain mapping typology. This seven‐map typology is based on the different wastes inherent in value streams. The use of the various tools…

42123

Abstract

Develops a new value stream or supplychain mapping typology. This seven‐map typology is based on the different wastes inherent in value streams. The use of the various tools, either singularly or in combination, is therefore driven by the types of waste to be removed. The tools themselves are drawn from a range of existing functional ghettos such as logistics, operations management and engineering. Maintains that two of the seven tools can be regarded as completely new. This cross‐functional approach means that the choice of tools to be used can be made from outside of traditional departmental boundaries, affording researchers and companies the opportunity to use the most appropriate tools rather than merely those that are well‐known in their function. Describes each tool briefly and gives a simple mechanism for choosing which is most appropriate to contingent situations.

Details

International Journal of Operations & Production Management, vol. 17 no. 1
Type: Research Article
ISSN: 0144-3577

Keywords

Article
Publication date: 2 May 2008

Dinesh Seth, Nitin Seth and Deepak Goel

The purpose of this paper is to identify and address various wastes in the supply chain of the edible cottonseed oil industry (specifically the processing side) using a value

7384

Abstract

Purpose

The purpose of this paper is to identify and address various wastes in the supply chain of the edible cottonseed oil industry (specifically the processing side) using a value stream mapping (VSM) approach to improve productivity and capacity utilization in an Indian context.

Design/methodology/approach

Critical observations and interviewing techniques were used with open‐ended questions to understand the processes involved in the value chain of the cottonseed oil industry. Different chain links/members were investigated through personal visits and discussions. VSM is applied as an approach to the industry to identify and remove non‐value‐adding (NVA) activities.

Findings

Major findings obtained from the study are as follows. There is an excess cumulative inventory of 244 days in the whole supply chain. The industry is highly fragmented with a large number of small players present, which hampers the use of economies of scale. There are NVA activities present in the supply chain such as the moving of cottonseed oil from expeller mill to refinery. The industry still uses outdated technology which hampers the productivity.

Practical implications

Attention needs to be given to boosting the productivity of the oil sector. Waste removal from the oilseed‐processing sector is one key to improving the productivity of the sector.

Originality/value

The paper addresses the various wastes in the processing side of the supply chain of the Indian cottonseed oil industry, using VSM as an approach which was hardly ever attempted before. Wastes are then individually attacked to reduce or eliminate them from the system. Suggestions to make the whole chain more productive can be generalized and can be replicated in the context of other developing countries.

Details

Journal of Manufacturing Technology Management, vol. 19 no. 4
Type: Research Article
ISSN: 1741-038X

Keywords

Article
Publication date: 25 June 2021

Anuj Dixit, Srikanta Routroy and Sunil Kumar Dubey

The requirement of high-quality government-supported healthcare services has necessitated the significance of recognizing new management practices to enhance patient satisfaction…

Abstract

Purpose

The requirement of high-quality government-supported healthcare services has necessitated the significance of recognizing new management practices to enhance patient satisfaction. Hence, the purpose of this study is to address the patient's enhanced custom needs through the implementation of supply chain value stream mapping (SCVSM) in government-supported drug distribution system (DDS) for enhanced patient's satisfaction.

Design/methodology/approach

This study elucidates the role of one popular emerging management technique (i.e. SCVSM) in the healthcare sector by an investigative case study. The DDS in Rajasthan (India) was selected for this study. The data for this analysis were gathered in three ways (i.e. direct observation, documentary analysis and semi-structured interviews).

Findings

The outcome of this current study reveals that it is possible to apply the tool (SCVSM) to investigate the wastes in DDS to deliver the medicines at right time, right quantity and right quality. The application of SCVSM concluded that the various Kaizens (areas needed to improve) in lead time; transportation and routing should be adopted. The study further implemented kaizen on the current SCVSM and developed future SCVSM.

Research limitations/implications

Although various stages and functions exist in the healthcare supply chain, the current study is focused on the distribution system of drugs. The proposed approach provides a platform for both researchers and academicians to understand the existing DDS and to implement the SCVSM approach in the healthcare environment. The results show that the proposed SCVSM model is able to identify some operational bottlenecks and wastes which interfere in DDS.

Originality/value

It was observed that limited literature related to lean implementation on DDS and implementation of SCVSM on the healthcare environment in general and government-supported or public in specific are available. The current study on the application of SCVSM in DDS is unique in nature and will definitely add value to the existing literature of the application of value stream mapping (VSM) on the healthcare supply chain management field.

Details

International Journal of Quality & Reliability Management, vol. 39 no. 5
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 1 April 1997

Daniel T. Jones, Peter Hines and Nick Rich

Sets out an alternative approach to designing and managing a logistics system, which is called here lean logistics. Draws on research which has sought to extend the production…

25576

Abstract

Sets out an alternative approach to designing and managing a logistics system, which is called here lean logistics. Draws on research which has sought to extend the production system logic pioneered by Toyota beyond the factory gate and into industries other than automobiles. Starts by outlining the dilemma facing managers trying to implement new business practices and then proposes an alternative way of rethinking the logic of value creation, before illustrating how this works in a complete logistics system. Central to this new logic is a detailed understanding of the waste or inefficiencies that lie in existing systems. Such an understanding is required so that radical or incremental improvements can then be made in the development of a lean logistics system. Presents a framework to do just this called value stream mapping. Illustrates the approach with an example from the distribution industry. Also raises a number of key questions for the academic community in terms of future research and applications within the broad area of lean logistics.

Details

International Journal of Physical Distribution & Logistics Management, vol. 27 no. 3/4
Type: Research Article
ISSN: 0960-0035

Keywords

Article
Publication date: 4 April 2023

Deedar Hussain and Manuel Carlos Figueiredo

The evaluation of time-based performance is a valued approach in the lean management thinking which is based on delivering value from customer's perspective. This approach…

879

Abstract

Purpose

The evaluation of time-based performance is a valued approach in the lean management thinking which is based on delivering value from customer's perspective. This approach contributes for long-term competitiveness and success in today's business environment. The focus of this study is to analyse the cycle time and manufacturing lead time with value stream mapping (VSM) in the preparatory stage of the textile fabric manufacturing process and to identify and improve the non-value adding activities in the value chain (VC). The study presents an insight on the translation of performance improvement across functions and how upstream supply chain (SC) segments can be linked in the performance improvement program. It also covers how the application of VSM improves visibility and planning flexibility in textile fabric manufacturing process.

Design/methodology/approach

The time-based performance was evaluated using VSM and recording of the activity times in the existing process. The impact of the quality of supplier's raw material was also measured contributing to identify the strategy for procurement and the means to establish a feedback system to the upstream segments of the SC. The methodology of VSM, observation of the practice and the expertise of the individuals involved with the process were utilised to develop the value stream maps and to identify value adding activities, non-value adding activities, existing gaps and plans for improvement.

Findings

The means for improving the time-based performance were identified and their impact was measured. The factors responsible for improvement are related to the production system and with the procurement strategy. The improvement was achieved in terms of available capacity utilisation, balancing the work flow in the preparatory stages, visibility of the process by measuring its capability and flexibility for the planning function. The study revealed that the effectiveness and enhancement of VSM and related tools should be adopted to address the issue of limiting success rates of long term and repeating application of such tools. Continuous improvement, innovations and the systematic embedding of VSM in the process life cycle provide the ways for achieving long-term success.

Research limitations/implications

The paper presents a real and in-depth study on the application of VSM in the textile manufacturing process. The scope of the study is broad; it covers activities across functions with actual estimates of activity times in the manufacturing process for the focused value streams. It offers researchers the opportunity to analyse the translation of productivity improvement across functions and how upstream SC segments can be linked in a performance improvement program.

Practical implications

The study offers useful insight for the managers in textile manufacturing and other sectors for improving the time-based performance and achieving higher utilisation of capacity. It identified the production factors and their impact on warping and sizing cycle time in selected value streams and those which share common activities. It also identified the directions for future research when repeating the application of VSM in the continuous improvement cycle. Furthermore, since the industries need to progress towards advanced systems including Industry 4.0 standards, adoption of advanced VSM tool with relevant technology can align their production systems to develop the required capability. This will also bring a sustainable competitive advantage in the system.

Social implications

The focused sector is stagnant in terms of productivity and innovation. The adoption of the advanced tools can facilitate the implementation of continuous improvement and innovation strategies.

Originality/value

The main focus of this study is to analyse and improve the cycle time in the preparatory stage of the fabric manufacturing process. This has impact on other important and tangible measures including capacity utilisation and work flow and intangible measures including production planning flexibility and process visibility. The improvement impact is across departments.

Details

Business Process Management Journal, vol. 29 no. 3
Type: Research Article
ISSN: 1463-7154

Keywords

Article
Publication date: 1 May 2006

A. Keivan Zokaei and David W. Simons

A key vision of tomorrow's industry is creating supply chains which collaboratively strive on enhancing the value to the end‐consumer. The purpose of this paper is to introduce…

9202

Abstract

Purpose

A key vision of tomorrow's industry is creating supply chains which collaboratively strive on enhancing the value to the end‐consumer. The purpose of this paper is to introduce the food value chain analysis (FVCA) methodology for improving consumer focus in the agri‐food sector based on the lean paradigm, value stream mapping and value chain analysis (Porter, 1985).

Design/methodology/approach

This contribution presents a case‐study of a UK red meat supply chain explaining how the FVCA method enabled a team of researchers and practitioners to identify the misalignments of both product attributes and supply chain activities with the consumer needs.

Findings

This paper explains how the FVCA methodology potentially realigned the processes along the supply chain with the true consumer requirements and why the supply chain effectiveness was improved; this follows with a description of the subsequent efficiency gains from application of the FVCA methodology.

Originality/value

This paper further defines the demarcation between supply chain “effectiveness” and “efficiency”. This paper contributes to the debate on the importance of supply chain effectiveness by linking to consumer value at every stage of the supply chain.

Details

The International Journal of Logistics Management, vol. 17 no. 2
Type: Research Article
ISSN: 0957-4093

Keywords

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