Lean production system design for fishing net manufacturing using lean principles and simulation optimization

Title: Lean Office in the public sector: Proposal for the Auction Section of a Teaching Unit. Objective of the work: The presente study aims to elaborate a proposal of the value flow of the internal phase of the auction process for the hiring of services of a continuous nature, adapted to the reality of IF Sudeste MG – Campus Barbacena, preserving legal aspects that govern the public administration. Procedures / Methods for Problem Solving: To diagnose the problem, data were collected from documental research, semi-structured interviews and participant observation. Lean Philosophy techniques were used and Case Study was taken as research strategy, wich made it possible to investigate in depth the selected product family for value stream mapping and achievement of objectives. Results: The selected product family was the internal phase of the auction process for contracting continuous services of unarmed patrimonial surveillance. The main technique used was the Current State Value Stream Mapping. The Process had a 71% Efficiency, a Lead Time of 113 days, the waste found as waiting time, transportation, movement and defect were treated with Kaizen event indications in Future State Value Stream Mapping, which reduced the lead time of the process to 73 days. Pratical Inplications: The model proposed in the Future State Value Stream Mapping was presented to managers and discussed until the consensus of the possibility of applicability of the Solution Proposal. Originality and contributions: The originality of the research can be caracterized by its construction based on a concrete case wicho sought in the literature techniques adopted to solve similar problems already addressed in the scientific community through Lean Philosophy. Technical / Technological Production: The Future State Map and the procedures for reaching the future state is the Technical / Technological product derived from this research. The future state to be achieved will bring innovation in the production of auction prcesses, strengthen teamwork and from small improvements, it will shape a culture of continuous process improvement.

Value Stream Mapping (VSM) is a tool for Lean Manufacturing which is used in mapping and identifying of all the specific actions required to eliminate the non-value activities manufacturing processes. Glides are essentially plastic components manufactured for supporting beds and sofas (legs). Due to globalisation and rapid advances in manufacturing technology, Small to Medium Enterprises (SMEs) involved in the manufacturing of Glides also need to move with the times and be able to adapt to new situations and VSM is the tool for that. This paper seeks to address the application of Value Stream Mapping to the production line for Glides with the aim of eliminating wastes and improving quality in the production of Glides. The current state map (CSM) was designed, analysed and suggestions were then given to improve the operational process while the future state map (FSM) was drawn for lean implementation.

Purpose: Lean manufacturing, originating from the Toyota Production System (TPS), aims to reduce waste and optimize resources. Developed countries must adopt Lean practices for performance improvements while developing countries often use just-in-case approaches. Value Stream Mapping (VSM) is a crucial tool for diagnosing, implementing, and maintaining Lean Manufacturing, helping identify improvement opportunities and eliminating waste. The research at the company aims to eliminate Lean wastes and line unbalancing issues to improve lead time and the value-added ratio (VAR), enhancing production efficiency. The research aligns with Sustainable Development Goal 12 (Responsible Production & Consumption) by focusing on waste reduction. Methodology: The research uses time study, Edaw max, and Visio software to analyze tasks, create VSMs of current and future states, and control charts to examine data variations over time. Data collection involves cycle time, batch size, packet size, and the number of workers required for each activity. Findings: The research objectives include studying the existing scenario of production units via VSM, identifying, and eliminating Lean wastes, and comparing proposed and existing scenarios for improvement opportunities. The literature review highlights the importance of Lean manufacturing in eliminating unnecessary processes, reducing lead time, and fostering positive stakeholder relationships. Unique Contribution to Theory, Practice and Policy: This study suggests the better way to reduce the lean wastages and balance the line by using VSM technique. The future state VSM is created to conceptualize potential improvements and gather feedback, focusing on reducing non-value-adding tasks, work-in-process inventory, workforce, and overall process time.

Value stream mapping is an important lean manufacturing tool used to improve business in a competitive market by eliminating non-value adding activities or wastes from the value stream of a product and improving in providing in process operations. This paper aims to address the application of lean manufacturing using value stream mapping (VSM) concepts in a casting organisation. Using value stream concepts, both current and future states maps of the organisation's shop floor scenarios have been discussed. Results of investigation demonstrated the net reduction of 14.28% in value added time and net cycle time of operation is reduced from 12 minutes to 9 minutes. Current state map and future state map are compared and important benefits occurred after successful implementation of VSM has been discussed and it leads to profit of about 357000 rupees annually.

Design and evaluation of a Lean Manufacturing framework using Value Stream Mapping (VSM) for a plastic bag manufacturing unit

Purpose: The aim of this paper is to show a successful improvement in operations with the implementation of lean manufacturing strategies in a Caribbean oil and gas company. Design/Methodology: Initially, a review of literature was performed on lean manufacturing (LM) tools. Then interviews and GEMBA walkthrough was carried out in the selected case organisation followed by the problems faced were analysed using value stream map (VSM) together with root cause analysis tools. At the end, future state VSM was developed and the benefits due to implementation of LM principles were quantified. Findings: The study revealed that a traditional approach is currently being used on the shop floor thus increasing the opportunity for hidden wastes between the processes as well as increased repair time due to defective equipment. The results concluded that improved shop floor utilisation, reduction in preparation time and hidden wastes were identified on the shop floor. Originality/value: The review of literature indicated that implementation of the lean principles in the Caribbean oil and gas sector has not been explored. Further, the study results provide a road map for similar organisations to achieve operational improvement but also is valuable for academic and research community for practical implementation of lean principles.

Performance-enhancing efforts in the manufacturing industry have centred on ‘lean’ principles and philosophies since the early 1970s. Lean principles, philosophies, tools and methods have also been significantly deployed to enhance performance in service processes within the manufacturing industry, as well as the process industry (e.g. inspection, maintenance and modification-related). It has been observed that when the main business is mostly centred on service-providing processes, significantly less effort is put into exploiting the use of lean approaches to enhance performance. Therefore, it is vital to investigate the potential of ‘lean’ concepts’ implementation in a service-providing organisation. This manuscript is based on the value stream mapping and the value stream analysis (VSA) performed in a Polish telecommunication-industry-related service-providing company. A plain old telephone services-based case study is presented. The service-providing process is analysed in order to identify the current existing drawbacks and to propose improvements to enhance performance. Based on the current state value stream map and the VSA results, a future state value stream map was developed. Then, process efficiency was calculated in order to assess the level of performance improvement.

PurposeOne 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/approachIn 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.FindingsThe 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/implicationsThough 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 implicationsThis 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/valueThis 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.

PurposeLean construction is a technique that aims at reducing waste in construction and maximizing productivity. The purpose of this paper is to discuss the effectiveness of Lean technique in managing construction projects.Design/methodology/approachA case study of structural steel erection project was chosen where the value stream mapping lean tool is applied and the possible improvement in productivity was observed. The current state of the activities in the erection process was mapped first which was followed by preparing the Future State Map of the activities after eliminating the non-value adding tasks.FindingsThe modifications from Future State Map were carried out at the project and the results exhibited a substantial increase in productivity by reducing the project duration by 13 days which is about 30 per cent savings from the expected completion time after the implementation of Lean technique.Originality/valueTraditionally lean concept has been widely used in process-oriented manufacturing industry whereas it is relatively new to the project-oriented construction industry. This current research has focused on applying lean tool to a real time construction project at the site level and measuring its outcome practically. The results of this study are real and affirm the effectiveness of applying lean concept to construction projects. It will be major paradigm shift in terms of managing construction projects.

The automotive industry in Thailand have competed fiercely, especially second-tier and third-tier automotive part manufacturers. They are hence impelled to apply technology 4.0 (i.e. robots, automation, and internet of thing). The technology 4.0 application is however achieved when logistics activities are leaned along their value streams. The lean logistics aims to add more values using value stream mapping (VSM). It supports to visualize a current state map of logistics activities along their value stream. The current state map facilitates to analyze the most critical problems having the highest non-value added. They are then overcome with suitable solutions whereas a future state map is drawn. In an industrial case, the most critical activities are case, disc, and cover lathing and washing; and heating respectively. They are replaced by technology 4.0 i.e. robot arms, induction machines, and conveyors in order to shorten cycle time and lead time. They lead to increase value-added ratio.

Value stream mapping to reduce the lead-time of a product development process

JK Tofu SME still faces obstacles in meeting market demand due to wasteful activities in the production process, such as excessive soybean soaking time and inconsistent and unmeasured yeast addition. This study aims to identify factors affecting tofu production process quality and process requirement standards. The methods used are quantitative approaches through DPMO calculations, Value Stream Mapping, and QFD. The results show that the production process still has defects such as dirty, smelly, and soft tofu. Current Value Stream Mapping analysis indicates low efficiency with a PCE of 51.67% and non-value-added time (NVA and NNVA) of 290 minutes. After improvements through Future State Mapping, the PCE increased to 71.26% and the total process time decreased to 435 minutes. The average DPMO of 33,333.33 with a sigma level of 1.933 indicates that quality is still far from Six Sigma standards. Through QFD Levels 1–3, consumer needs are translated into technical specifications, product characteristics, and production process requirements. Specifications such as ingredient composition and cooking processes influence product quality, while integration across QFD levels strengthens quality control. QFD provides strategic and operational guidance for continuous product quality improvement. This study shows that analyzing the causes of waste can affect product quality and that it is necessary to determine process requirement standards.

Value addition and performance improvement are important to deal with increasing local and global market competitiveness. Interventions and automation based on Lean and ergonomics principles have strong influence on performance improvement of the production systems. This study focuses on implementation of lean manufacturing and ergonomics principles to improve work environment and performance of the soccer manufacturing production line. Work visualization and value stream mapping (VSM) techniques were employed to identify the opportunities for improvements. Time of value and non-value-added activities is recorded using time study method. Working postures and associated risk factors are evaluated using Rapid Entire Body Assessment (REBA) method. Lean manufacturing principles are employed to minimize wastes and non-value added activities. Similarly, improvements in work environment are made through ergonomics interventions. Various models comprising different levels of lean and ergonomics interventions were evaluated through simulation before actual implementation. The results of the finalized model in terms of decrease in cycle time (8.64 to 7.018 seconds), increase in daily production (20505 to 24176 soccer balls), and improved work environment are evident of performance improvements in all aspects. The integration of lean and ergonomics principles leads to improve the productivity and working environment for workers in soccer ball manufacturing industry.

Leveraging lean principles in creating a comprehensive quality program: The UCLA health readmission reduction initiative

The adoption of lean principles and the establishment of a lean culture are continuing trends in both construction and post-construction buildings. This paper will examine how lean principles and fire safety management practices are integrated into the design, supply, construction, occupation, refurbishment, and demolition phases of the Private Al-Quran Memorization (Tahfiz) School (PTS). A deadly fire at Pusat Tahfiz Darul Quran Ittifaqiyah, a religious school in Kampung Datuk Keramat, in 2017, and other fire incidents that caused heightened attention on safety in these institutions led to the start of this study. This poses a significant challenge that requires immediate attention to the infrastructure and fire prevention systems of PTS. It is important to effectively implement fire safety measures to protect people, school buildings, and property from the catastrophic effects of fire. To address this issue, Lean Principles are being adopted in fire safety management, with a focus on the performance of the PTS infrastructure as a prevention approach. Lean Principles are commonly used in Lean Manufacturing, Lean Design, Lean Construction, and Lean Maintenance, and have been widely accepted by professionals worldwide. Prevention through Design (PtD) can be initiated as a general prevention principle, with various Lean Tools implemented throughout the PTS building lifecycle, including designing, construction, occupying, demolishing, and modification processes. Despite the integration of Lean Principles into fire safety engineering is yet to be studied and introduced effectively, the framework has potential benefit in developing legislation, rules, guidelines, and good practise in the government/regulatory body that could enhance the fire prevention system in the PTS.