A Analysis of Factors Affecting Waste Using Value Stream Mapping (VSM) On Kaosbekas.Id (original) (raw)
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Lean Manufacturing: Waste Reduction Using Value Stream Mapping
E3S web of conferences, 2018
Cristal Sri Sujarwati is a small medium enterprise (SME) that produce keripik salak in Sleman, Yogyakarta. To survive and win industrial competition, Cristal Sri Sujarwati was required to improve its performance. But in reality there was a lot of waste in order fulfillment processes marked by ineffective and inefficient work. In this research, lean manufacturing aims to identify and eliminate waste so that the company could improve its performance in winning the industry competition. Lean manufacturing is a systematic approach used to identify and eliminate waste. This lean concept could improve responsiveness through waste reduction, continuous improvement and cost reduction. In order to identify and eliminating waste, a value stream mapping tools, waste weighting questionnaire, value stream analysis tools, and fishbone diagram are used. From the results of research, the dominant waste in the production process was waste defects, waiting, and unnecessary inventory. To eliminate waste, process activity mapping (PAM), the one of detailed mapping tools in VALSAT are used. From the results of the improvement recommendations analysis, lead time decreased by 80 minutes. From the analysis using PAM, there was a reduction of NVA activity from 3.10% to 1.01%.
2011
Value Stream Mapping (VSM) is a World Class Manufacturing tool that can be used to minimise waste in manufacturing. Companies are experiencing intense competitive pressure due to globalisation hence they cannot afford to operate with waste in their processes. This paper details the use of the VSM tool in reducing waste in bread manufacturing for a company in Zimbabwe. The case study shows how the VSM tool was used to identify and reduce defects by 20%, unnecessary inventory by 18% and motion by 37%. It incorporates waste relationship ranking and the importance of management commitment in waste reduction.
Since its beginning, lean manufacturing has built a worldwide reputation based on results related to production improvement and cost reduction in several companies. This management philosophy focuses on customer value creation through the elimination of production wastes. Lean methods and techniques have spread their scope from the automotive industry to a wide range of industries and services. This article presents a case study that describes the use of the lean tool value stream mapping in the production process of automotive parts for a major automotive company. At the beginning of the project, relevant data from the process were collected and analysed. Subsequently, the initial process was mapped, the related wastes were identified, and then future processes were mapped and financial results were estimated. The proposals were presented on kaizen meetings, the action plan was discussed and the decision regarding which option to choose was taken. Consequently, the Cycle Time and the level of the workforce were reduced, the process was improved and savings were obtained.
JURNAL Al-AZHAR INDONESIA SERI SAINS DAN TEKNOLOGI
This research is based on the fact that many domestic sugar industries operate inefficiently and have low productivity, which is seen when compared to other countries such as Thailand, India and Australia. This study aims to identify and analyze problems along the flow of the white crystal sugar production process that cause waste and then make suggestions for improvements to reduce existing waste to increase cost efficiency in the production process. The national sugar factories generally have a basic problem, namely the low level of factory efficiency, which causes a lot of waste along the flow of the production process. The right concept for solving this problem is the implementation of the Lean manufacturing method, where this method focuses on efforts to reduce waste along the flow of the production process by making continuous improvements. The research begins with a literature study and field study and then conducts observations, analyzes, brainstorms, extracts and collects d...
International Journal of Production Management and Engineering, 2019
Companies around the world are under pressure to reduce their prices to be competitive. In order to keep profitability, they are adopting lean manufacturing (LM) and its tools to reduce waste and, consequently, the costs. Value stream mapping (VSM) is an efficient LM tool, identifying production flow waste. When it is possible to combine VSM with other LM tool, such as Kanban, a substantial impact in inventory reduction is reached. Additionally, the conventional account system shows limitations in the costs reduction to keep up with LM. The purpose of this paper is to present the results obtained by the application of the VSM combined with Kanban and the new account approach to measure the effectiveness of the cost reduction in the finished goods inventory. Considering that LM tools application in the textile segment has not an expressive number of researches, four hypothesis are presented and validated. The findings are discussed and finally, the research limitations and the practi...
MATEC Web of Conferences, 2018
Batik is one of Indonesian cultural heritage that confirmed by United Nations of Educational, Scientific, and Cultural Organization (UNESCO) on October 2009. This legal confirmation improves the number of batik industry from many regions based its local unique characteristic. The increasing number of batik SMEs in Indonesia requires a strategy that can create competitive advantage. This strategy can be done by reducing production waste. One of Indonesian batik SMEs is SME Batik CM located in Yogyakarta. There are several problems that occur in the industry, i.e. length of the production process, spots on Batik and excessive raw materials inventory. Based on that problems, this research is done by applying lean manufacturing concept using value stream mapping (VSM) method to evaluate production wastes. Based on the result of the research, there are seven types of production waste: overproduction (9,62%), inventory (17,3%), defect (23,08%), motion (9,62%), transportation (9,62%), Over processing (9,62%) and waiting (21,15%). Process improvement is done to reduce the highest waste, defect, using quality filter mapping (QFM).
2004
The main objective of this work of thesis is the formulation of a frame of reference, by means of an analysis of the application of a Lean Manufacturing tool (Value Stream Mapping) in various processes of diverse companies of different maturity levels in the Manufacturing sector to help them see the optimizations that can be attained trough the use of this tool. In the development of this thesis, an investigation of Value Stream Mapping (Lean Manufacturing tool) and its strategy of implementation were made. The author of the present document made a series of practical cases applying this tool with the purpose of making an analysis in order to find the most important elements and than that would be useful to integrate them in a frame of reference. Once realized the analysis, the author developed and proposed a model as well as a frame of reference that can serve as guide for people whom they want to use the value stream map tool. The results obtained when applying the practical cases offer interesting results that allow to see the benefits that an organization could obtain when doing use of a tool like this, as well as, this investigation allows to see possible future investigations that they reinforce and they improve the model and the frame of reference proposed here.
IOP Conference Series: Materials Science and Engineering
This paper describes how to apply both of value stream mapping tools and kanban system for identifying and reducing wastes that happened on shop-floor. This research was conducted at a basic chemical company which produces the thinner. This study aims to reduce even to eliminate the types of waste that occur on the production line of jerrycan product type. The plot of VSM is used to picture the entire of value stream. The value stream mapping tools are used to analyze the certain waste after it has been figured out by using waste assessment model. Hence in this study two selected tools were applied and discussed further, i.e. process activity mapping, and supply chain response matrix. The Current-VSM shown that value-added time of 472.33 s compared with total lead time of 132,568.76 s, consequently obtained process cycle efficiency (PCE) approximately 0.36%. Kanban system will be implemented to eliminate waste of unnecessary inventory throughout the value stream. At last, the result...
APPLICATION OF VALUE STREAM MAPPING IN BHUJIA MANUFACTURING
Value stream mapping is an enterprise improvement tool to help in visualizing the entire production process, representing both material and information flow. A value stream is all the actions (both value added and non-value added) required to bring a product through the main flows essential to every product for the production flow from raw material into the arms of the customer. Value stream mapping (VSM) is a tool of lean manufacturing. The ultimate goal of Value stream mapping is to identify all types of waste in the value stream and to take steps to try and eliminate these. In the present research paper, a food industry (Bhujia manufacturing industry) have been considered with current state maps and future state maps after following the different steps starting from the detailed time study for mapping the processes from raw materials to final product. Value stream mapping captures the information at individual's stations about cycle time, set up time, WIP (Work in Process) inventory, manpower requirement and the information flow from raw materials to final product. The overall non value added time is reduced during Bhujia manufacturing process.