Process mapping improvement: Extending value stream maps with waste identification diagrams (original) (raw)
Related papers
Waste identification diagram and value stream mapping
International Journal of Lean Six Sigma, 2019
PurposeThe purpose of this paper is to compare the well-known value stream mapping (VSM) with a recent tool named waste identification diagram (WID), regarding the capacity of information representation and easiness of interpretation.Design/methodology/approachThe work begins with a brief literature review comparing the main tools for representation of production units, with special emphasis on VSM and WID, in terms of ability to identify several types of waste. Then, the authors developed the VSM and the WID of a specific production unit and after that several groups composed by students of Industrial Engineering (IE) and/or professionals from industry were asked to analyse/interpret only one of these diagrams. Finally, a questionnaire with closed and open questions was applied to the groups to evaluate the analysed tool.FindingsIn general, the results revealed that WID is more effective than VSM and participants recognized that most of the WID elements are relevant. Specifically, ...
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...
A Analysis of Factors Affecting Waste Using Value Stream Mapping (VSM) On Kaosbekas.Id
Jurnal Entrepreneur dan Entrepreneurship, 2022
Lean manufacturing approach is a systematic approach which identifies and eliminates waste through continuous improvement: the flow of products that customers want to pursue the perfection. This study aims to determine the amount of waste in Kaosbebas.id and examine the causes of the waste by using Value Stream Mapping (VSM), value stream analysis tools, and fishbone diagrams. At the beginning of the study, the description of the current state map was carried out for the analysis of the fulfilment of the physical flow and the flow of information on the production of Kaosbebas.id. After weighting the waste, the researchers distributed questionnaires to informants related to the custom T-shirt production process to obtain the results of identifying the locations of waste and what things made the waste occur during the production process. Furthermore, the researchers conducted an evaluation process so that this waste reduction is expected to increase production efficiency and improve company performance. In addition, this study also aims to provide suggestions for improvements to the manufacture of custom t-shirts during the production process. This study uses a qualitative approach with the methods of observation, interviews, and questionnaires.
A Review on Waste Reduction through Value Stream Mapping Analysis
Manufacturers face cost-reduction and efficiency challenges in their operations. They need to find ways to reduce production time, costs and eliminate waste in order to improve operating performance and product quality to survive in today's highly competitive world, Value Stream Mapping (VSM) technique involves flowcharting the steps, activities, material flows, communications, and other process elements that are part of the transformation process. In this respect, Value Stream Mapping helps an organization to identify the non-value-adding elements in a targeted process and brings a product or a group of products that use the same resources through the main flows, from raw material to the arms of customers. This paper discusses the method of Value Stream Mapping and its benefit to different industries. The paper also presents a Literature Review to summarize the various applications of this technique and improvements achieved in lead time, cycle time and inventory reduction by various industries. The paper concludes with highlighting VSM's important contribution to revealing and curtailing extravagances in the target process.
2020
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 i...
Waste identification diagrams with OEE data
2014
Existing techniques to represent production units are not very effective in representing several dimensions of production, limiting the extent to which diagnose and problem identification is accrued. Value Stream Mapping is one such technique which, although very popular among lean practitioners, exhibits a number of practical limitations. In this paper the authors present the all new Waste Identification Diagram, encompassing a number of new features and improved graphics capabilities, which makes it a feasible alternative technique to that of VSM, while extending its breath of application by integrating Overall Equipment effectiveness data into the diagrams. An example application of the WID technique to a real production unit will be presented, screening its effectiveness for diagnosing problems, measuring performance and providing key visual information and precious clues for improvement.
Value Chain Development as Alternative Method for Mapping Waste Management
Journal of Innovation in Business and Economics, 2017
Solid Waste management begin at the household as waste of consumption and ended as a new form of waste product or recycling. Based on its value chain the subsequent process will have distict differences with manufacturing product. Value chain of manufacturing product will characterize as value added chain along the chain, where every side of the chain will generate positive chain. In the other hand, some parties of waste management value chain will negative value existed. Some parties in this chain will generate negative value solely because they must establish some cost for wipe the waste. Dissimilarities between value chain on product and waste will contribute to discrepancy between parties. Main purpose of this research is to identify value chain from solid waste management using value chain development. Another purpose to accomplished is to resolve discrepancy in value chain. Research results shown that household is the parties that experiences negative value. To minimize the d...
Waste flow mapping to improve sustainability of waste management: a case study approach
Journal of Cleaner Production, 2015
An efficient Waste Management System creates increased business value contributing to manufacturing industry sustainability and realizes economic opportunities. Previous studies have shown the economic potential of improving material efficiency by climbing the waste hierarchy and turning waste liabilities into assets. World economic forum also identifies innovation for resource efficient solutions and business models as the most strategic option to capture value in industry. The main responsibility for waste lies with the operations owner but since waste management usually is operated by other functions or companies, supportive methods to include material waste in operational development are needed. The main purpose of the research has therefore been to develop a method framework for identifying and analysing potentials for waste management in manufacturing industry, including residual material values of metals, combustible and inert waste, process fluids and other hazardous waste. Case studies were conducted to find economically competitive environmental improvements on team, site and multisite level and to define suitable performance indicators for continuous improvements. A novel approach: waste flow mapping (WFM), combining Value Stream Mapping (VSM), Eco mapping and a waste composition analysis with basic lean principles is used. The material's value flow and the information flow is analysed in a VSM. Eco-mapping is used to give a graphical structure for the analysis of labour and equipment, with subsequent costs. Finally the waste hierarchy and composition analysis is used to imply the potential for business improvements and best practice examples are used. The developed method reveals the potential in an easy way and support integration of waste management in operations and continuous improvement work. Empirical data from a full scale multi-site study of waste management of material residuals at a global manufacturing company's operations in Sweden are used to exemplify that with the WFM approach the mapping can be done in an efficient and consistent manner, revealing value losses and improvement potentials. Fraction definitions and operational practice standards were essential to realise cost efficiency and reach a more sustainable footprint. Comparisons between sites show that with simple actions, substantial improvements in recycling efficiency can be made, leading to proposed performance indicators and highlighting the need for established standardized implementation solutions. The results further point out the importance of avoiding mixing material with lower quality grade of that material. The experiences prove that Waste Flow Mapping is a suitable method to efficiently identify sustainability improvement potentials.
Waste Flow Mapping: Improve sustainability and realize waste management values
An efficient Waste Management System creates increased business value, contributes to sustainability and realizes economic opportunities. Previous studies have shown the potential of improving the economy of material efficiency by turning waste liabilities into assets and innovation of resource-efficient solutions and business models is identified by World Economic Forum as the most strategic option to capture value in industry. The main responsibility for waste lies with the operation’s owner but since waste management usually is operated by other functions or companies, supportive methods to include material waste in operational development are needed. The main purpose of this research has been to develop a method framework for identifying and analysing potentials for waste management in manufacturing industry, including residual material values of metals, combustible and inert waste, process fluids and other hazardous waste. A novel approach: Waste Flow Mapping (WFM) is used, combining Value Stream Mapping (VSM), Eco-mapping and a waste composition analysis with basic lean principles to imply the business improvement potentials. Case studies were conducted to validate the approach and to define suitable performance indicators for continuous improvements. Best practice examples were used to support integration of waste management in operations and continuous improvement work. Empirical data from a full scale multi-site study at a global manufacturing company’s operations in Sweden show that by using the WFM approach, the mapping can be done in an efficient and consistent manner, revealing value losses and improvement potentials. Fraction segment definitions were essential to realise cost efficiency and reach a more sustainable footprint. Comparisons between sites show that with simple actions, substantial improvements in recycling efficiency can be made, leading to proposed performance indicators and highlighting the need for established standardized implementation solutions. The results further point out the importance of avoiding mixing material with lower quality grade of the same material.
Value Stream Mapping as a Basis for Waste Removal in the Agri-Food Industry
2021
The case company is a Swedish family-owned business, operating in the agri-food industry. Their philosophy is to develop, produce, and sell frozen products from the vegetable kingdom with a focus to be organic and convenient. The company has realized that the production layout and the material flow cause a lot of waste and have great potential for improvements regarding efficiency in production and related processes. Value stream mapping (VSM) will be used to identify and reduce waste at the company. In addition, there is a gap in knowledge when it comes to the use of VSM in agri-food production. Therefore, a comparison of the use of VSM in the agri-food industry to a previously (well) studied industry will be made. Purpose: The purpose of this study was to analyse the current production setup and the related processes at the case company using VSM, to test its applicability in the agri-food industry and how it differs from a previously well studied industry. Research questions: RQI What waste can be identified by VSM and how does that affect the business? RQ2 How can the identified waste be reduced? RQ3 How does the use of VSM in the agri-food industry differ from a previously (well) studied industry? Method: A combination of an inductive and deductive approach was chosen in this study, and a descriptive and explanatory strategy was used. Further, it was chosen to do a single case study. A combination of primary, secondary data, qualitative and quantitative data was used. Conclusions: The study showed several types of waste affecting the business: waiting, transportation, unnecessary inventory, and defects. The authors were able to find root causes of the identified waste and based on this, several suggestions that could potentially reduce the identified waste were presented. The use of VSM in the agri-food industry was found a good tool to identify and potentially eliminate waste. However, some differences between the use of VSM in the agri-food industry and a previously (well) studied industry were found.