Yalın üretim için değer akış haritalandırma ve simülasyon: Mobilya sektöründe bir uygulama

Yıl 2017, Cilt: 23 Sayı: 4, 462 - 469, 18.08.2017

Hacer Güner Gören

Öz

Pazarda yoğun rekabetin artması sonucu, yalın prensipler birçok işletme tarafından takip edilmektedir. Bu prensipler, israfları azaltarak ve yok ederek operasyonların etkinliğini artırmaya odaklanmaktadır. Yalın olabilmek için ise birçok değişik teknik ve yöntem uygulanmaktadır. Bu tekniklerden biri de kolaylıkla farklı sektörlere uygulanabilen Değer Akış Haritalandırmadır (DAH). Fakat, DAH sadece bir organizasyonun mevcut durumunu gösteren statik bir araçtır. Bu eksikliği giderebilmek adına, önerilen iyileştirmelerin değerlendirilmesini kolayca yapabilen simülasyon yardımcı teknik olarak yaygın olarak kullanılmaktadır. Bu çalışma, israfın çok olduğu mobilya sektörüne yönelik DAH ve simülasyonu birleştiren bir endüstriyel uygulama örneği sunmaktadır. Belirlenen bir ürün ailesine yönelik iyileştirme önerileri ile birlikte mevcut ve gelecek durum haritaları DAH kullanılarak açıklanmıştır. Bir simülasyon modeli oluşturularak “önce” ve “sonra” senaryoları detaylı olarak analiz edilmiştir.

Anahtar Kelimeler

Değer akış haritalandırma, Simülasyon, Mobilya sektörü, Yalın üretim

Value stream mapping and simulation for lean manufacturing: A case study in furniture industry

Öz

Lean principles have been followed by many organizations in recent years due to the increase of tough competition in the market. These principles focus on improving the efficiency of operations by eliminating and reducing wastes. Different techniques and methods have been applied in order to become lean. One of them is the Value Stream Mapping (VSM) which can be easily applied in a variety of industries. However, VSM is a static tool which only shows the current state of the organization. To deal with this shortcoming, simulation is widely used as a complimentary technique in which the assessment of the impact of proposed improvements can be easily analyzed. This paper presents an industrial case example combining VSM and simulation in furniture industry in which there are a lot of wastes to deal with. Both current and future state maps for a particular product family are described by VSM following the suggestions for improvement. A simulation model is also developed to show the “before” and “after” scenarios in detail.

Anahtar Kelimeler

Value stream mapping, Simulation, Furniture industry, Lean manufacturing

Kaynakça

• Womack JP, Jones DT. Lean thinking: banish waste and create wealth in your corporation. Simon & Schuster, New York, USA, 1996.
• Holweg M. “The genealogy of lean production”. Journal of Operations Management, 25(2), 420-437, 2007.
• Fujimoto T. The Evolution of a Manufacturing System at Toyota. New York, USA, Oxford University Press, 1999.
• Hines P, Holweg M, Rich N. “Learning to evolve: A review of contemporary lean thinking”. International Journal of Operations & Production Management, 24(10), 994-1011, 2004.
• Seth D, Gupta V. “Application of value stream mapping for lean operations and cycle time reduction: an Indian case study”. Production Planning and Control, 16(1), 44-59, 2005.
• Rother M, Shook J. Learning to see: Value stream mapping to add value and eliminate MUDA. The Lean Enterprise Institute, Brookline, MA, 1999.
• McDonald T, Van AEM, Rentes AF. “Utilizing simulation to enhance value stream mapping: A manufacturing case application”. International Journal of Logistics Research Applications, 5(2), 213-232, 2002.
• Rahani AR, Al-Ashraf M. “Production flow analysis through value stream mapping: A lean manufacturing process case study”. Procedia Engineering, 41, 1727- 1734, 2012.
• Belokar RM, Kumar V, Kharb SS. “An application of value stream mapping in automative industry: A case study”. International Journal of Innovative Technology and Exploring Engineering, 1(2), 152-157, 2012.
• Shingo S. A Study of the Toyota Production System. Cambridge: Productivity Press, 1989.
• Halpin DW, Kueckmann M. “Lean construction & simulation”. Proceedings of the Winter Simulation Conference, Arlington, USA, 9-12 December 2001.
• Abdulmalek FA, Rajgopal J. “Analyzing the benefits of lean manufacturing and value stream mapping via simulation: a process sector case study”. International Journal of Production Economics, 107(1), 223-236, 2007.
• Staats BR, Brunner DJ, Upton DM. “Lean principles, learning, and knowledge work: Evidence from a software services provider”. Journal of Operations Management, 29(5), 376-390, 2011.
• Teichgräber UK, de Bucourt M. “Applying value stream mapping techniques to eliminate non-value-added waste for the procurement of endovascular stents”. European Journal of Radiology, 81(1), 47-52, 2012.
• Robinson S, Radnor ZJ, Burgess N, Worthington C. “SimLean: Utilising simulation in the implementation of lean in healthcare”. European Journal of Operational Research, 219(1), 188-197, 2012.
• Villarreal B, Garza F, Rosas I, Garcia D. “An introduction to distribution operational efficiency”. International Journal of Industrial Engineering: Theory, Applications and Practice, 19(7), 278-288, 2012.
• Chen JC, Cheng CH, Huang PoTB. “Supply chain management with lean production and RFID application: A case study”. Expert Systems with Applications, 40(9), 3389-3397, 2013.
• Rohac T, Januska M. “Value stream mapping demonstration on real case study”. Procedia Engineering, 100, 520 529, 2015.
• Vlachos I, Bogdanovic A. “Lean thinking in the European hotel industry”. Tourism Management, 36, 354-363, 2013.
• Chong MY, Prakash J, Ling Ng S, Ramli R, Chin JF. “Parallel kanban-ConWIP system for batch production in electronics assembly”. International Journal of Industrial Engineering: Theory, Applications and Practice, 20(7), 2013.
• Acharya TK. “Material handling and process improvement using lean manufacturing principles”. International Journal of Industrial Engineering: Theory, Applications and Practice, 18(7), 357-368, 2011.
• Tyagi S, Choudhary A, Cai X, Yang K. “Value Stream Mapping to reduce the lead-time of a product development process”. International Journal of Production Economics, 160, 202-212, 2015.
• Brown A, Amundson J, Badurdeen F. "Sustainable value stream mapping (Sus-VSM) in different manufacturing system configurations: Application case studies". Journal of Cleaner Production: Special Issue on Lean and Green Initiatives, 85, 164-179, 2014.
• Sundar R, Balaji AN, Kumar RM, Satheesh Kumar RM. “A review on lean manufacturing implementation techniques”. Procedia Engineering, 97, 1875-1885, 2014.
• Singh B, Garg SK, Sharma SK. “Value stream mapping: literature review and implications for Indian industry”. International Journal of Advanced Manufacturing Technology, 53(5), 799-809, 2011.
• Disney SM, Naim MM, Towill DR. “Dynamic simulation modelling for lean logistics”. International Journal of Physical Distribution & Logistics Management, 27(3-4), 174-96, 1997.
• Huang CC, Liu SH. “A novel approach to Lean control for Taiwan-funded enterprises in mainland China”. International Journal of Production Research, 43(12), 2553-2575, 2005.
• Lian Y, Van Landeghem H. “Analysing the effects of Lean manufacturing using a value stream mapping-based simulation generator”. International Journal of Production Research, 45(13), 3037-3058, 2007.
• Al-Aomar R. “Handling multi-lean measures with simulation and simulated annealing”. Journal of the Franklin Institute, 348(7), 1506-1522, 2011.
• Baysan S, Cevikcan E, Satoglu ŞI. “Assessment of Energy Efficiency in Lean Transformation: A Simulation Based Improvement Methodology”. In Assessment and Simulation Tools for Sustainable Energy Systems (pp. 381-394). Springer London, 2013.
• Standridge, C. R., Marvel, J. H. “Why lean needs simulation”. In Proceedings of the 38th conference on winter simulation (pp. 1907-1913). Winter Simulation Conference, 2006.
• Bin Ali N, Petersen K, Nicolau de França BB. “Evaluation of simulation-assisted value stream mapping for software product development: Two industrial cases”. Information and Software Technology, 68, 45-61, 2015.
• Yang T, Kuo Y, Su C-T, Hou C-L. “Lean production system design for fishing net manufacturing using lean principles and simulation optimization”. Journal of Manufacturing Systems, 34(1), 66-73, 2015.
• Bulut, K., Altunay, H. “Değer akışı haritalandırma yöntemi: mobilya sektöründe bir uygulama”. Kırıkkale Üniversitesi Uluslararası Mühendislik Araştırma ve Geliştirme Dergisi, 8(1), 48-55, 2016.