Productivity improvement by embedded value stream mapping (VSM) and simulation in assembly manufacturing company

Muhamad Sukri, Khairiah (2022) Productivity improvement by embedded value stream mapping (VSM) and simulation in assembly manufacturing company. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Lean Manufacturing (LM) is a successful global method used in business sectors to enhance operations continuously. LM is a way for businesses to be ahead of the competition by making manufacturing systems more productive and efficient. With higher advanced technology, the industrial environment has taken manufacturing systems to a new level known as Industrial 4.0. In this study, combination of Value Stream Mapping (VSM) and Arena Simulation Software as LM tools to eliminate waste during the production process. Research has been published on the practical application of VSM and Arena simulation, proving that performance has improved. A Case study to resolve the manufacturing company's current situation regarding the production line's output needed to meet the company's target. This company generates too many LM Motion and Waiting Waste in the production lines. Motion waste occurs because there is an unnecessary movement by the manpower of the production line due to the sharing robots simultaneously at the right and left sides. For waiting, there are Non-Value-Added processes (NVA) identified from the kitting process to the child part inspection. Therefore, this study aims to apply the VSM and Arena Simulation to overcome the waste in the production line by mapping and analyzing the current state process to suggest the best solution for the company to increase productivity. The combination method with Discrete Model Simulation (DES) allows for monitoring the line production in a virtual model using the simulation model. An Arena simulation model can be used to make strategic decisions to improve the production line output. As a result, the company's production line suggested running one side only at one time in the production line to increase daily output from 120 units per day to 132 units, showing that the productivity increased by 10 %. There are currently eight operators on the production line, but only four will be assigned under the proposed solution. The number of operators used in the inspection process is reduced, which benefits the company by lowering costs. Thus, the company's operational performance will improve, and this research objective will be achieved.

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