Application of Value Stream Mapping (VSM) in a Sewing Line for Improving Overall Equipment Effectiveness (OEE): A Case Study

  • Shawkat Imam ShakilEmail author
  • Mahmud Parvez
Conference paper
Part of the Smart Innovation, Systems and Technologies book series (SIST, volume 169)


Value stream mapping (VSM) has been successfully applied to improve OEE and other performance parameters in a sewing line of VIP Industries Ltd. Improvement scopes have been identified from the current state map, and rough set theory has been adopted to identify focused areas and improvement strategy regarding where and how lean control should be approached. After that, two new layouts have been designed. Different performance parameters are calculated for both of the layouts and compared with the existing layout. New layout 2 exhibited the most promising outcome and is selected as the proposed layout. Production lead time, inventory and processing time are visualized in the future state VSM based on the proposed layout. Finally, OEE improved from 45 to 53.75%. This methodology is suitable for manufacturing environment having process layout and achieves the goals of reducing waste and improving productivity and performance.


Value stream mapping Rough set theory OEE Layout redesign Lean manufacturing 


  1. 1.
    Rother, M., Shook, J.: Learning to see: value stream mapping to add value and eliminate MUDA. The Lean Enterprise Institute, Brookline, MA (1999)Google Scholar
  2. 2.
    Garg, D., Desmukh, S.G.: JIT purchasing: literature review and implications for Indian industry. Prod. Plan. Control 10(3), 276–285 (1999)CrossRefGoogle Scholar
  3. 3.
    Hines, P.: Value stream management: next frontier in supply chain? Logist Focus 1(3), 36–39 (1999)MathSciNetGoogle Scholar
  4. 4.
    Arbulu, R., Iris, T., Walsh, K., Hershauer, J.: Value stream analysis of a re-engineered construction supply chain. Build. Res. Inf. 31(2), 161–171 (2003)CrossRefGoogle Scholar
  5. 5.
    Dhandapani, V., Potter, A., Nain, M.: Applying lean thinking: a case study of an Indian steel plan. Int. J. Logistics Res. Appl. 7(3), 239–250 (2004)CrossRefGoogle Scholar
  6. 6.
    Grewal, C.S.: An initiative to implement lean manufacturing using value stream mapping. Int. J. Manuf. Technol. Manag. 15(3–4), 404–417 (2008). Scholar
  7. 7.
    Serrano, I., Ochoa, C., de Castro, R.: Evaluation of value stream mapping in manufacturing system redesign. Int. J. Prod. Res. 46(16), 4409–4430 (2008). Scholar
  8. 8.
    Womack, J.P., Jones, D.T.: Lean thinking: banish waste and create wealth in your corporation. Simon & Schuster, New York (1996)Google Scholar
  9. 9.
    Barker, R.C.: The design of lean manufacturing systems using time-based analysis. Int. J. Oper. Prod. Manag. 14(11), 86–96 (1994)CrossRefGoogle Scholar
  10. 10.
    Monden, Y.: Toyota Production System: an integrated approach to just-in- time, 2nd edn. Industrial Engineering and Management Press, Norcross, GA (1993)CrossRefGoogle Scholar
  11. 11.
    Womack, J.P., Jones, D.T., Roos, D.: The machine that changed the world. Macmillan, New York (1990)Google Scholar
  12. 12.
    Chitturi, R.M., Glew, D.J., Paulls, A.: Value stream mapping in a jobshop. In: IET International Conference on Agile Manufacturing, ICAM 2007, 9–11 July 2007, pp. 142–147 Google Scholar
  13. 13.
    Disney, S.M., Naim, M.M., Towill, D.R.: Dynamic simulation modeling for lean logistics. Int. J. Phys. Distrib. Logist. Manag. 27(3/4), 174–196 (1997)CrossRefGoogle Scholar
  14. 14.
    McDonald, T., Van Aken, E.M., Rentes, A.F.: Utilizing simulation to enhance value stream mapping: a manufacturing case application. Int. J. Logist. Res. Appl. 5(2), 213–232 (2002).
  15. 15.
    Huang, C.C., Liu, S.H.: A novel approach to lean control for Taiwan funded enterprises in mainland China. Int. J. Prod. Res. 43(12), 2553–2577 (2005)Google Scholar
  16. 16.
    Comm, C.L., Mathaisel Dennis, F.X.: A paradigm for benchmarking lean initiatives for quality improvement. Benchmarking Int. J. 7(2), 118–127 (2000)CrossRefGoogle Scholar
  17. 17.
    Hines, P., Rich, N., Esain, A.: Value stream mapping a distribution industry application. Benchmarking Int. J. 6(1), 60–77 (1999)CrossRefGoogle Scholar
  18. 18.
    McManus, H.L., Millard, R.L.: Value stream analysis and mapping for product development. In: Proceedings of the International Council of the Aeronautical Sciences 23rd ICAS Congress, Toronto Canada, pp. 8–13 (2002)Google Scholar
  19. 19.
    Pawlak, Z.: Rough Sets: Theoretical Aspects of Reasoning About Data, Kluwer Academic Publishers, Norwell, MA (1991)Google Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2020

Authors and Affiliations

  1. 1.Khulna University of Engineering and TechnologyKhulnaBangladesh

Personalised recommendations