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Value stream mapping with lean thinking model for effective non-value added identification, evaluation and solution processes

Author

Listed:
  • Rosmaini Ahmad

    (Universiti Malaysia Perlis)

  • Rabiatul Fakhira Mohd Amin

    (Universiti Malaysia Perlis)

  • Shaliza Azreen Mustafa

    (Universiti Malaysia Perlis)

Abstract

The effectiveness of the application of value stream mapping (VSM) highly relies on the analysis of current state mapping (CSM) that focuses on identification, evaluation and solution processes of the non-value added (NVA) activities. The conventional application of VSM is performed for these processes using the “effect-based solution” approach. Here, the effects of NVA activities (known as production waste), such as defects, lead time, bottlenecks, etc. are separately identified and evaluated before being related to Lean tools for solution. These tools then recommend ways to eliminate/minimize waste. This conventional approach, however, will lead to unstable solution for long term practice due to its mechanism in targeting the effect as a primary solution rather than the root cause of the effect. In the literature, there are very limited works highlighting these processes in systematic, practical and effective ways. Therefore, this paper introduces a methodology called the VSM-Lean Thinking (VSM-LT) model to improve the analysis of CSM. Then, guides a feasible solution identification before it can be visualized in future state mapping (FSM). The key idea behind this VSM-LT model is to identify and evaluate the root cause of the waste as revealed by CSM. The waste is then treated by solving the identified root cause(s) as a primary solution target. The model provides a chain-effect relationship mapping platform to identify and evaluate the root cause (s). It can be carried out based on four steps; NVA effect identification, LT-based operation features deficiency matching, possible root cause(s) mapping and solution identification & mechanism description. The model is then validated using a case study in a small medium enterprise (SME) of the food-based manufacturing industry. Validation results showed that multiple NVA activities visualized through CSM, come from one similar root cause. Therefore, feasible solution strategies and mechanisms are then recommended. Based on identified root causes, the FSM is then presented to visualize the improvement. Related measures of expected improvement are then compared. In overall, the proposed model is significantly beneficial for VSM practitioners to improve the analysis and evaluation of CSM towards identifying more sustainable solutions for their industry-based operational problems.

Suggested Citation

  • 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.
    • Handle: RePEc:spr:opmare:v:15:y:2022:i:3:d:10.1007_s12063-022-00265-9
    DOI: 10.1007/s12063-022-00265-9
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    References listed on IDEAS

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    1. 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.
    2. Lage Junior, Muris & Godinho Filho, Moacir, 2010. "Variations of the kanban system: Literature review and classification," International Journal of Production Economics, Elsevier, vol. 125(1), pages 13-21, May.
    3. Foivos Psarommatis & Gökan May & Paul-Arthur Dreyfus & Dimitris Kiritsis, 2020. "Zero defect manufacturing: state-of-the-art review, shortcomings and future directions in research," International Journal of Production Research, Taylor & Francis Journals, vol. 58(1), pages 1-17, January.
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