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Waste Reduction in Production Processes through Simulation and VSM

Author

Listed:
  • Stefania Bait

    (Department of Enterprise Engineering, Tor Vergata University of Rome, 00133 Via del Politecnico, Italy)

  • Alessandro Di Pietro

    (Operations Excellence Think Tank, Tor Vergata University of Rome, 00133 Via del Politecnico, Italy)

  • Massimiliano M. Schiraldi

    (Department of Enterprise Engineering, Tor Vergata University of Rome, 00133 Via del Politecnico, Italy)

Abstract

Corporate managers often face the need to choose the optimal configurations of production processes to reduce waste. Research has shown that simulation is an effective tool among those conceived to support the manager’s decisions. Nevertheless, the use of simulation at the company level remains limited due to the complexity in the design phase. In this context, the Value Stream Map (VSM)—a tool of the Lean philosophy–is here exploited as a link between the strategic needs of the management and the operational aspect of the simulation process in order to approach sustainability issues. The presented approach is divided into two main parts: a set of criteria for expanding the VSM are identified in order to increase the level of details of the represented processes; then, data categories required for the inputs and outputs of each sub-process modeling are defined, including environmental indicators. Specifically, an extended version of the classical VSM (X-VSM), conceived to support process simulation, is here proposed: the X-VSM is used to guide the design of the simulation so that the management decisions, in terms of waste reduction, can be easily evaluated. The proposal was validated on a production process of a large multinational manufacturing company.

Suggested Citation

  • Stefania Bait & Alessandro Di Pietro & Massimiliano M. Schiraldi, 2020. "Waste Reduction in Production Processes through Simulation and VSM," Sustainability, MDPI, vol. 12(8), pages 1-14, April.
    • Handle: RePEc:gam:jsusta:v:12:y:2020:i:8:p:3291-:d:347037
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    References listed on IDEAS

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    1. Alexander Sunk & Peter Kuhlang & Thomas Edtmayr & Wilfried Sihn, 2017. "Developments of traditional value stream mapping to enhance personal and organisational system and methods competencies," International Journal of Production Research, Taylor & Francis Journals, vol. 55(13), pages 3732-3746, July.
    2. Yang, Ma Ga (Mark) & Hong, Paul & Modi, Sachin B., 2011. "Impact of lean manufacturing and environmental management on business performance: An empirical study of manufacturing firms," International Journal of Production Economics, Elsevier, vol. 129(2), pages 251-261, February.
    3. Abdulmalek, Fawaz A. & Rajgopal, Jayant, 2007. "Analyzing the benefits of lean manufacturing and value stream mapping via simulation: A process sector case study," International Journal of Production Economics, Elsevier, vol. 107(1), pages 223-236, May.
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    Cited by:

    1. Vanessa Rodríguez Cornejo & Ángel Cervera Paz & Luis López Molina & Víctor Pérez-Fernández, 2020. "Lean Thinking to Foster the Transition from Traditional Logistics to the Physical Internet," Sustainability, MDPI, vol. 12(15), pages 1-17, July.
    2. Shahin Ghaziani & Gholamreza Dehbozorgi & Mohammad Bakhshoodeh & Reiner Doluschitz, 2023. "Identifying Loss and Waste Hotspots and Data Gaps throughout the Wheat and Bread Lifecycle in the Fars Province of Iran through Value Stream Mapping," Sustainability, MDPI, vol. 15(10), pages 1-24, May.
    3. Ana Colim & Rita Morgado & Paula Carneiro & Nélson Costa & Carlos Faria & Nuno Sousa & Luís A. Rocha & Pedro Arezes, 2021. "Lean Manufacturing and Ergonomics Integration: Defining Productivity and Wellbeing Indicators in a Human–Robot Workstation," Sustainability, MDPI, vol. 13(4), pages 1-21, February.
    4. Yilmaz, Aysegul & Dora, Manoj & Hezarkhani, Behzad & Kumar, Maneesh, 2022. "Lean and industry 4.0: Mapping determinants and barriers from a social, environmental, and operational perspective," Technological Forecasting and Social Change, Elsevier, vol. 175(C).

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