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A simulation-enhanced value stream mapping approach for optimisation of complex production environments

机译：一种模拟增强的价值流映射方法，用于优化复杂的生产环境

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摘要

Value stream mapping (VSM) is a widely adopted method for transformation of production environments into a lean operational state. The straightforwardness as well as the completeness, with which processes are analysed and optimised, are key to the success of the method originating from the automotive industry. However, these attributes of the 'paper and pencil' approach result in limitations when applying VSM in complex production environments. This research paper targets to overcome these limitations, specifically in production environments involving significant demand variability, complex routing and cost factors which potentially increase with lean implementation. For this purpose, an enhanced VSM method is developed, which utilises discrete event simulation (DES). The method features a feasibility and tradeoff analysis which is incorporated into the VSM procedure. A case study covering a process of exhaust gas purification catalyst production is then conducted to test the newly developed method. The VSM project yields a shop floor lead time reduction from 11.4 to 1.4 d. The additional DES feasibility and trade-off analysis determines customer demand fulfilment and quantifies the monetary benefit of the future state. In that way, potential iterative implementation which is inherently oppositional to the lean philosophy is avoided.
机译：价值流映射（VSM）是一种广泛采用的方法，用于将生产环境转换为精益操作状态。对过程进行分析和优化的简单性和完整性是源自汽车行业的方法成功的关键。但是，“纸笔”方法的这些属性在复杂的生产环境中应用VSM时会受到限制。本研究论文旨在克服这些限制，特别是在涉及明显的需求可变性，复杂的工艺路线和成本因素的生产环境中，这些环境可能会随着精益实施而增加。为此，开发了一种增强的VSM方法，该方法利用了离散事件模拟（DES）。该方法具有可行性和权衡分析功能，已纳入VSM程序。然后进行案例研究，涉及废气净化催化剂的生产过程，以测试新开发的方法。 VSM项目的车间交货周期从11.4天减少到1.4天。额外的DES可行性和权衡分析确定了客户需求的满足情况，并量化了未来状态的货币收益。以此方式，避免了潜在地与精益哲学相反的迭代实现。

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