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A new value stream mapping approach for complex production systems

A new value stream mapping approach for complex production systems In this paper, an innovative framework to apply Value Stream Mapping to products with complex Bill of Materials is presented. Value Stream Mapping is one of the best tools to map a process and to identify its main criticalities. Unfortunately, it can be effectively applied to linear systems only. When the manufacturing process is complex with flows merging together, Value Stream Mapping cannot be used straightforwardly. Thus, the main objective of this work is to solve this limitation so that lean production can be enhanced in complex systems too. The proposed approach is based on seven iterative steps and integrates Value Stream Mapping with other tools typical of industrial engineering. The basic idea is to execute a preliminary analysis to identify the ‘critical production path’ using the Temporized Bill of Material. Then, improvements are made considering all possible sharing with other secondary paths as possible constraints. Once the critical path has been optimized, a new path may become critical. Thus, the analysis proceeds iteratively until the optimum is reached and the Work In Process level has decreased under a desired value. A case study taken from a real setting environment is finally presented to assess the validity of the methodology proposed here. http://www.deepdyve.com/assets/images/DeepDyve-Logo-lg.png International Journal of Production Research Taylor & Francis

A new value stream mapping approach for complex production systems

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References (14)

Publisher
Taylor & Francis
Copyright
Copyright Taylor & Francis Group, LLC
ISSN
1366-588X
eISSN
0020-7543
DOI
10.1080/00207540600690545
Publisher site
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Abstract

In this paper, an innovative framework to apply Value Stream Mapping to products with complex Bill of Materials is presented. Value Stream Mapping is one of the best tools to map a process and to identify its main criticalities. Unfortunately, it can be effectively applied to linear systems only. When the manufacturing process is complex with flows merging together, Value Stream Mapping cannot be used straightforwardly. Thus, the main objective of this work is to solve this limitation so that lean production can be enhanced in complex systems too. The proposed approach is based on seven iterative steps and integrates Value Stream Mapping with other tools typical of industrial engineering. The basic idea is to execute a preliminary analysis to identify the ‘critical production path’ using the Temporized Bill of Material. Then, improvements are made considering all possible sharing with other secondary paths as possible constraints. Once the critical path has been optimized, a new path may become critical. Thus, the analysis proceeds iteratively until the optimum is reached and the Work In Process level has decreased under a desired value. A case study taken from a real setting environment is finally presented to assess the validity of the methodology proposed here.

Journal

International Journal of Production Research – Taylor & Francis

Published: Sep 15, 2006

Keywords: Lean manufacturing; Routing; Temporized bill of material; Value stream mapping

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