{"title":"Mapping the path to efficiency: harnessing value stream mapping (VSM) and lean tools for streamlined electronic device manufacturing","authors":"Mohammad Al-Rifai","doi":"10.1108/mbe-06-2024-0087","DOIUrl":null,"url":null,"abstract":"<h3>Purpose</h3>\n<p>Optimizing manufacturing processes addresses operational challenges and yields significant benefits across the business spectrum. This study aims to comprehensively analyze a manufacturing process through value stream mapping (VSM), aiming to streamline operations, reduce production lead times and minimize work-in-process (WIP) inventory levels. These improvements directly enhance competitiveness, customer satisfaction and overall business success, enabling a swift response to market demands, timely delivery of high-quality products and cost-effectiveness.</p><!--/ Abstract__block -->\n<h3>Design/methodology/approach</h3>\n<p>The approach integrates current and future-state VSM concepts with Lean tools across four stages: problem definition, current-state VSM analysis, future-state VSM design and improvement implementation. A team assembled to improve the manufacturing process for electronic devices has successfully implemented this approach.</p><!--/ Abstract__block -->\n<h3>Findings</h3>\n<p>Implemented improvements significantly reduced WIP inventory (88.8% equivalent to $572,171 annually) and production lead time (from 28.26 to 3.21 days), enhancing operational flexibility and competitiveness. Streamlined processes led to a 13% decrease in cycle time and a notable reduction in daily rework (63.6%), amounting to $118,127 annually. Labor reduction (45.5%) yielded annual savings of approximately $594,000, with affected individuals successfully transitioning to other roles, highlighting the effectiveness of lean methodologies without job cuts.</p><!--/ Abstract__block -->\n<h3>Originality/value</h3>\n<p>This initiative exemplifies the effective use of VSM and Lean tools in optimizing an electronic device manufacturing operation that produces 43 products across various processes. By leveraging these methodologies, this research offers valuable insights into enhancing production efficiency, resulting in shorter production lead times, reduced cycle times and significant decreases in WIP inventory and rework.</p><!--/ Abstract__block -->","PeriodicalId":18468,"journal":{"name":"Measuring Business Excellence","volume":null,"pages":null},"PeriodicalIF":2.5000,"publicationDate":"2024-08-22","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":"0","resultStr":null,"platform":"Semanticscholar","paperid":null,"PeriodicalName":"Measuring Business Excellence","FirstCategoryId":"1085","ListUrlMain":"https://doi.org/10.1108/mbe-06-2024-0087","RegionNum":0,"RegionCategory":null,"ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":null,"EPubDate":"","PubModel":"","JCR":"Q3","JCRName":"BUSINESS","Score":null,"Total":0}
引用次数: 0
Abstract
Purpose
Optimizing manufacturing processes addresses operational challenges and yields significant benefits across the business spectrum. This study aims to comprehensively analyze a manufacturing process through value stream mapping (VSM), aiming to streamline operations, reduce production lead times and minimize work-in-process (WIP) inventory levels. These improvements directly enhance competitiveness, customer satisfaction and overall business success, enabling a swift response to market demands, timely delivery of high-quality products and cost-effectiveness.
Design/methodology/approach
The approach integrates current and future-state VSM concepts with Lean tools across four stages: problem definition, current-state VSM analysis, future-state VSM design and improvement implementation. A team assembled to improve the manufacturing process for electronic devices has successfully implemented this approach.
Findings
Implemented improvements significantly reduced WIP inventory (88.8% equivalent to $572,171 annually) and production lead time (from 28.26 to 3.21 days), enhancing operational flexibility and competitiveness. Streamlined processes led to a 13% decrease in cycle time and a notable reduction in daily rework (63.6%), amounting to $118,127 annually. Labor reduction (45.5%) yielded annual savings of approximately $594,000, with affected individuals successfully transitioning to other roles, highlighting the effectiveness of lean methodologies without job cuts.
Originality/value
This initiative exemplifies the effective use of VSM and Lean tools in optimizing an electronic device manufacturing operation that produces 43 products across various processes. By leveraging these methodologies, this research offers valuable insights into enhancing production efficiency, resulting in shorter production lead times, reduced cycle times and significant decreases in WIP inventory and rework.
期刊介绍：
Measuring Business Excellence provides international insights into non-financial ways to measure and manage business performance improvements and company’s value creation dynamics. Measuring Business Excellence will enable you to apply best practice, implement innovative thinking and learn how to use different practices. Learn how to use innovative frameworks, approaches and practices for understanding, assessing and managing the strategic value drivers of business excellence. MBE publishes both rigorous academic research and insightful practical experiences about the development and adoption of assessment and management models, tools and approaches to support excellence and value creation of 21st century organizations both private and public.
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