Lean production system design for fishing net manufacturing using lean principles and simulation optimization |
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| Affiliation: | 1. Institute of Manufacturing Information and Systems, National Cheng Kung University, Tainan 701, Taiwan;2. Department of Industrial Engineering and Management, Ming Chi University of Technology, New Taipei City 243, Taiwan;3. Department of Industrial Engineering and Engineering Management, National Tsing Hua University, Hsinchu 300, Taiwan;1. Department of Fashion Technology, National Institute of Fashion Technology, New Delhi, India;2. Department of Fashion Technology, National Institute of Fashion Technology, Jodhpur, India;1. Department of Industrial and Systems Engineering, University of Tennessee, Knoxville, TN, United States;2. Radiochemical Science and Engineering Group, Nuclear Security and Isotope Technology Division, Oak Ridge National Laboratory, Oak Ridge, TN, United States;1. Department of Mechanical Engineering, Saveetha School of Engineering, Saveetha University, Chennai 602 105, Tamil Nadu, India;2. Division of Physics, Department of Science and Humanities, Saveetha School of Engineering, Saveetha University, Chennai 602105, Tamil Nadu, India |
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| Abstract: | Value stream mapping (VSM) is a useful tool for describing the manufacturing state, especially for distinguishing between those activities that add value and those that do not. It can help in eliminating non-value activities and reducing the work in process (WIP) and thereby increase the service level. This research follows the guidelines for designing future state VSM. These guidelines consist of five factors which can be changed simply, without any investment. These five factors are (1) production unit; (2) pacemaker process; (3) number of batches; (4) production sequence; and (5) supermarket size. The five factors are applied to a fishing net manufacturing system. Using experimental design and a simulation optimizing tool, the five factors are optimized. The results show that the future state maps can increase service level and reduce WIP by at least 29.41% and 33.92% respectively. For the present study, the lean principles are innovatively adopted in solving a fishing net manufacturing system which is not a well-addressed problem in literature. In light of the promising empirical results, the proposed methodologies are also readily applicable to similar industries. |
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| Keywords: | Lean manufacturing Simulation Value stream mapping Fishing nets |
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