Lean thinking, value stream mapping and simulation applications for new production shop floor setup-a case study in food-based industry

This dissertation presents the application Lean Thinking (LT) through Lean Manufacturing approach to drive a smoothness of production flow systems as a case study research project in food processing industry. Value Stream Mapping (VSM) have known as one of the approaches that familiar applicate in manufacturing world. However, the effectiveness of this approach have seen slowly started to be implementing in the food-based processing industry. The fact that there are still lacking of studies of this approach is supported by literature review in this paper. It found that, most of the application of VSM approach only happens when the production has been existed. For this case study paper, the methodology applied is combination of elements LT and VSM. It can be divided into two main stages; the first stage is information/data gathering and the second stage is value stream mapping & simulation applications. The case study is planned to capture the possible problems in sequencing processes in new refinery shop-floor production line. So that, a proactive recommendation/solutions can be propose to ensure the smoothness of the production shop-floor area. After analyzing the simulation results from Current State Mapping (CSM) data, several blockage problems occur at sub-processes. Therefore, it also seems that a critical need to revise the production system within some processes. The basic idea is to look the possibility to combine push and pull system within these processes. The blockage issues are more complicated because of continuous flow system (push flow system) that cannot be stop. It also founded that the processing speed (conveyor speed) is not constant. The inconsistent speed of production flow is one of significant root cause to blockage problems that exists at production area. Another possible problem occurs involve quite rude mechanism of feeding, thus highly will cause dry rice vermicelli cake broken. Meanwhile, insufficient number of workers is detected in CSM development. Results of after forming the Future State Mapping (FSM), the combination of push and pull systems is the appropriate production control systems to control the smoothness of the production flow and specific Kanban system mechanism are proposed to control input-output process between the sub-processes, including withdrawal system (continuous pull material), compulsory continuous process, process speed setting, feeding process mechanism, and revise appropriate number of workers. Further research study can be carried out to do simulation to validate the Final-FSM to prove/disprove whether the operation parameters proposed and implemented were contributes in good state or not. In addition, future work also can seek for future analysis based on actual production data once all the production machines and equipment are install in the new company production floor. This study can be extended to include other variable that contributes to the data collection in the future. Further research also can be carried out to use VSM for products from other categories with using the same production line (if any).