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Value stream mapping and system dynamics integration for manufacturing line modelling and analysis

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  • Stadnicka, Dorota
  • Litwin, Paweł

Abstract

Companies have to meet clients' requirements with regard to product quality and delivery time. In order to survive and have possibilities to develop, companies should do it at minimal cost. The lean manufacturing implementation approach together with lean tools, such as value stream mapping (VSM), is an efficient way for waste identification and elimination. However, since VSM enables only a static analysis of a manufacturing system, the authors present in this paper how the integration of VSM with a system dynamics analysis (SDA) may increase the possibilities for waste identification and elimination. At first, the methodology of extended VSM is described. Then, an extended value stream map (VSMap) is developed and a system dynamics model (SDM) for a case study from the automotive industry is presented. Next, simulations in Vensim software are performed considering the inventory limitations and disturbances such as delivery delays, machine failures and nonconformities. The results are related to inventory levels, a number of manufactured products and work stand load. The article proves that the proposed extended VSM may be used as the only source of data for the construction of a manufacturing line computer model. The paper also argues that the integration of VSM and SD allows not only to identify and eliminate waste, but also to understand the impact of the identified problems on WIP and the production volume.

Suggested Citation

  • Stadnicka, Dorota & Litwin, Paweł, 2019. "Value stream mapping and system dynamics integration for manufacturing line modelling and analysis," International Journal of Production Economics, Elsevier, vol. 208(C), pages 400-411.
    • Handle: RePEc:eee:proeco:v:208:y:2019:i:c:p:400-411
    DOI: 10.1016/j.ijpe.2018.12.011
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    References listed on IDEAS

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    1. Mariusz Salwin & Ilona Jacyna-Gołda & Michał Bańka & Dari Varanchuk & Anna Gavina, 2021. "Using Value Stream Mapping to Eliminate Waste: A Case Study of a Steel Pipe Manufacturer," Energies, MDPI, vol. 14(12), pages 1-19, June.
    2. Rosmaini Ahmad & Rabiatul Fakhira Mohd Amin & Shaliza Azreen Mustafa, 2022. "Value stream mapping with lean thinking model for effective non-value added identification, evaluation and solution processes," Operations Management Research, Springer, vol. 15(3), pages 1490-1509, December.
    3. Mariusz Salwin & Karolina Pszczółkowska & Michał Pałęga & Andrzej Kraslawski, 2023. "Value-Stream Mapping as a Tool to Improve Production and Energy Consumption: A Case Study of a Manufacturer of Industrial Hand Tools," Energies, MDPI, vol. 16(21), pages 1-25, October.
    4. Boysana Lephoi Mbonyane & Charles Mbohwa & Jan Harm Christiaan Pretorius, 2023. "Physical and Technological Capital Efficiency for Profit Growth in Small and Medium Enterprises in Gauteng, South Africa: A Descriptive Qualitative Study," Sustainability, MDPI, vol. 15(8), pages 1-23, April.
    5. Yaroslava Kostiuk, 2022. "Influence of Quality on Manufacturing Processes in Enterprises from the Perspective of Generating Value Added," GATR Journals jfbr194, Global Academy of Training and Research (GATR) Enterprise.
    6. Yilmaz, Aysegul & Dora, Manoj & Hezarkhani, Behzad & Kumar, Maneesh, 2022. "Lean and industry 4.0: Mapping determinants and barriers from a social, environmental, and operational perspective," Technological Forecasting and Social Change, Elsevier, vol. 175(C).

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