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Article
Publication date: 4 November 2019

Shuqiang Wang, Jia Tang, Yiquan Zou and Qihui Zhou

The purpose of this paper is to investigate the process optimization of a precast concrete component production line by using value stream mapping.

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Abstract

Purpose

The purpose of this paper is to investigate the process optimization of a precast concrete component production line by using value stream mapping.

Design/methodology/approach

This paper is an empirical focused on of lean production theory and value stream mapping. The data in the case study were collected in real time on-site for each process during the production process of a prefabricated exterior wall.

Findings

The results of the current value stream map indicate that the main problems of the current production process are related to equipment, technology and organization. The equipment problems include simple demolding and cleaning tools and the lack of professional transfer channels. The technology problems include the lack of a marking mechanism and pipeline exit mechanism. There is a lack of standard operating procedures and incomplete process convergence. A comparison and analysis of the current value stream and the future value flow indicate that optimizations of the process flow, the production line layout, and the standard operating procedures have shortened the delivery cycle, reduced the number of workers, improved the operator’s operating level and balanced the production line.

Practical implications

The results of this study provide practitioners with a clear understanding of the optimization of the precast concrete component production and represent a method and basis for the process optimization of a factory production line; the approach is suitable for process optimization in other areas.

Originality/value

This research represents an innovative application of lean production theory and value stream mapping in a complex production line of precast concrete components and thereby fills the gap between the theory and practice of the optimization of a precast concrete component production line.

Details

Engineering, Construction and Architectural Management, vol. 27 no. 4
Type: Research Article
ISSN: 0969-9988

Keywords

Open Access
Article
Publication date: 28 September 2020

Jan Riezebos and Babette Huisman

Teachers of primary education experience high levels of stress but lack rational coping strategies to reduce their work stress. The paper develops a value stream mapping

2935

Abstract

Purpose

Teachers of primary education experience high levels of stress but lack rational coping strategies to reduce their work stress. The paper develops a value stream mapping for education approach and examines its use as a rational coping strategy for teams of teachers and other employees to overcome work-related stressors.

Design/methodology/approach

The research process consists of two phases. First, a value stream mapping approach for education is developed, based on literature research. Next, the approach is validated in an action research study to reduce work stress of teachers in educational services. The processes that have been selected by the teachers relate to coping with increased variety, long and uncertain throughput times and unclear specifications.

Findings

Value stream mapping for education (VSM4EDU) is a well-structured improvement method based on principles of visualization, participation and process thinking, which helps teachers without background in lean thinking to analyse their processes. Using this method has enabled the team to develop rational coping strategies to reduce their work-related stress.

Research limitations/implications

VSM4EDU has been validated using action research at a single school, which implicates deep insight, but further testing at other schools is welcome. Moreover, VSM4EDU has not been used to develop a future state map.

Practical implications

Value stream mapping is useful in educational settings as long as the educational context is respected in the approach.

Social implications

VSM4EDU empowers teachers and helps to develop co-operation in teams.

Originality/value

The validation of value stream mapping for education is well-documented and original.

Details

International Journal of Quality & Reliability Management, vol. 38 no. 4
Type: Research Article
ISSN: 0265-671X

Keywords

Article
Publication date: 1 December 2004

M.L. Emiliani and D.J. Stec

Presents for the first time how valuestream maps can be used to determine leadership beliefs, behaviors, and competencies. Current‐state valuestream maps represent…

10999

Abstract

Presents for the first time how valuestream maps can be used to determine leadership beliefs, behaviors, and competencies. Current‐state valuestream maps represent “conventional” management thinking and practices – what most business schools teach – while future‐state maps represent progressive “lean” management thinking and practices rooted in the Toyota management system. Current‐ and future‐state valuestream maps for manufacturing and service business processes are used to illustrate the progression from belief to behavior to competency. The beliefs, behaviors, and competencies of leaders skilled in these two modes of management thinking and practice are shown to be remarkably different, and constitute an alternative and simpler route for identifying leadership problems and improving leadership effectiveness.

Details

Leadership & Organization Development Journal, vol. 25 no. 8
Type: Research Article
ISSN: 0143-7739

Keywords

Article
Publication date: 1 January 1997

Peter Hines and Nick Rich

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

38727

Abstract

Develops a new value stream or supply‐chain 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: 12 June 2018

Ali-Asghar Dadashnejad and Changiz Valmohammadi

One of most important tools for lean production is value stream mapping (VSM), which identifies and reduces errors, losses, waiting time and improves value adding time…

1312

Abstract

Purpose

One of most important tools for lean production is value stream mapping (VSM), which identifies and reduces errors, losses, waiting time and improves value adding time, leading to enhanced product quality through empowering production unit in terms of production risk and cost reduction in the long term. This paper aims to present a general concept for production flow, such that value stream can be fully understood. For this purpose, this research investigates the effect of value stream on operational losses and analyzes the process that has been conducted in preview step operationally, using the discovered pattern.

Design/methodology/approach

In this research, related processes were evaluated after the review of the relevant literature and after extracting operational basics of lean approach using a questionnaire, such that all factors affecting operational losses and VSM were assessed. Then comparison between the result of current state map and the result of future state map were done and analyzed. Cronbach’s alpha was calculated to test the designed questionnaire’s reliability, which resulted in an acceptable level of 0.845. The structural equation modeling method through SPSS and Smart–Partial Least Square was applied to analyze the data and test the hypotheses.

Findings

The results reveal that implementing required changes and corrections will lead directly to production process improvement, which, in turn, results in higher customer satisfaction because of cost reduction and quality enhancement. Also, tests of the hypotheses confirm that VSM affects six operational losses, namely, equipment failures, set-up and changeovers, idling and minor stoppages, reduced speed operation, scrap and rework and startup losses.

Research limitations/implications

Though this study was done in a single manufacturing company, the implementation of this study delivers important results that can be deployed in other such manufacturing companies.

Practical implications

This tool helps to identify loss points, make right decisions, and choose the best methods and lean tools for improvement. The surveyed company can integrate lean principles and tools and achieve better results using this tool. Also, this tool could be used to analyze the process and to define necessary changes before changing the process components.

Originality/value

This study contributes to the body of knowledge in manufacturing research as the study regarding the effects of improvement opportunities identified through VSM on operational losses is still something new.

Details

Journal of Engineering, Design and Technology, vol. 16 no. 3
Type: Research Article
ISSN: 1726-0531

Keywords

Article
Publication date: 25 November 2020

Christer Hedlund, Petter Stenmark, Erik Noaksson and Johan Lilja

The purpose of this paper is to discuss recent trends in the circular economy and investigate how value stream mapping (VSM) can be extended to more fully include some of…

Abstract

Purpose

The purpose of this paper is to discuss recent trends in the circular economy and investigate how value stream mapping (VSM) can be extended to more fully include some of the critical aspects of circular economy.

Design/methodology/approach

The findings are based on previous research that has explored the usage of VSM to include aspects of the environment and sustainability aspects. These ideas are then expanded to new ways to use VSM by mapping value of a product as it is; used, maintained, re-used, remanufactured, recycled, incinerated or used for landfill. The authors test out this approach through application in the waste management sector to identify possibilities for improvement and new business opportunities in what now is considered waste.

Findings

This paper introduces an expanded version of VSM that refines the existing Lean toolbox for exploring value and mapping value in a circular economy.

Practical implications

The aim of this paper is to expand the relevance and practical value of VSM as the world economy increasingly moves toward a circular one.

Originality/value

Today, VSM is a widespread method within Lean manufacturing that scrutinizes value creation within an organization or within a value chain. This paper describes how VSM can be refined to explore value streams in the afterlife of a product and explore waste as a resource utilization opportunity.

Details

International Journal of Quality and Service Sciences, vol. 12 no. 4
Type: Research Article
ISSN: 1756-669X

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.

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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: 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…

24888

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: 1 April 2014

D.T. Matt

The purpose of this research is to examine relevant parts of the case of an Italian steel construction company's green field plant design process to identify best practice…

3771

Abstract

Purpose

The purpose of this research is to examine relevant parts of the case of an Italian steel construction company's green field plant design process to identify best practice guidelines for the adaptation and use of value stream mapping (VSM) in the design of lean engineer-to-order (ETO) production systems.

Design/methodology/approach

The paper reviews the most relevant literature in the field of VSM and discusses its limitations regarding the application in an ETO environment. Based on the analysis of an industrial case, the original VSM methodology is adapted with a special focus on ETO. Information was collected through multiple site visits and semi-structured interviews with the company's key staff of the project, as well as examination of relevant company documentations.

Findings

A set of guidelines was developed on the basis of an industrial case research. In this context, major attention was given to two aspects: the introduction of synchronization points in front of merge-activities in the value stream, and the splitting of customer orders into suitable production orders and equal time increments of work.

Research limitations/implications

The findings of this research are limited due to the focused nature of a case study-based research. However, the obtained results encourage assuming its transferability to similar problems.

Originality/value

This paper provides an original industrial case study with valuable insights for the adaptation of the VSM methodology to batch-of-one ETO environment.

Details

Journal of Manufacturing Technology Management, vol. 25 no. 3
Type: Research Article
ISSN: 1741-038X

Keywords

Book part
Publication date: 28 February 2017

Peter Hines, Daniel Jones and Nick Rich

Abstract

Details

Handbook of Logistics and Supply-Chain Management
Type: Book
ISBN: 978-0-8572-4563-2

1 – 10 of over 14000