Skip to main content

An Integrated Value Stream Mapping and Simulation Approach for a Production Line: A Turkish Automotive Industry Case

  • Conference paper
  • First Online:
Digitizing Production Systems

Abstract

Lean production practices are increasing day by day, especially in manufacturing companies, and in parallel with this situation, the importance given by companies to lean production concept is also increasing. Companies need continuous improvement, to be innovative, to identify problems in the system in a limited time and act in order to maintain their competitive strength in today’s environment . In this paper, under the roof of lean thinking and lean manufacturing concept, a literature review and simulation study for a manufacturing industry have been made on improvement studies, especially in the automotive sector, in an adaptation to Industry 4.0, and on the methods, frameworks and modelling used in these studies. Furthermore, the aim of the study is to guide the sectors to improve their processes by analysing the current situation with the concept of lean and making use of the necessary technologies and models. In the research, current and future situation analysis were made using lean production approach, the system was simulated with ARENA software and its performance was measured. Accordingly, a financial analysis of the proposed improvement and a decision were made.

This is a preview of subscription content, log in via an institution to check access.

Access this chapter

Chapter
USD 29.95
Price excludes VAT (USA)
  • Available as PDF
  • Read on any device
  • Instant download
  • Own it forever
eBook
USD 259.00
Price excludes VAT (USA)
  • Available as EPUB and PDF
  • Read on any device
  • Instant download
  • Own it forever
Softcover Book
USD 329.99
Price excludes VAT (USA)
  • Compact, lightweight edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info
Hardcover Book
USD 329.99
Price excludes VAT (USA)
  • Durable hardcover edition
  • Dispatched in 3 to 5 business days
  • Free shipping worldwide - see info

Tax calculation will be finalised at checkout

Purchases are for personal use only

Institutional subscriptions

References

  • Adel, A.A., Badiea, A.M., Albzeirat, M.K.: Techniques and assessment of lean manufacturing implementation: an overview. Int. J. Eng. Artif. Intell. 1(4), 35–43 (2020)

    Google Scholar 

  • Alefari, M., Almanei, M., Salonitis, K.: Lean manufacturing, leadership and employees: the case of UAE SME manufacturing companies. Prod. Manuf. Res. 8(1), 222–243 (2020)

    Google Scholar 

  • Andrade, P.F., Pereira, V.G., Del Conte, E.G.: Value stream mapping and lean simulation: a case study in automotive company. Int. J. Adv. Manuf. Technol. 85(1–4), 547–555 (2015). https://doi.org/10.1007/s00170-015-7972-7

    Article  Google Scholar 

  • Bai, C., Satir, A., Sarkis, J.: Investing in lean manufacturing practices: an environmental and operational perspective. Int. J. Prod. Res. 57(4), 1037–1051 (2019)

    Article  Google Scholar 

  • Basu, P., Dan, P.K.: A comprehensive study of manifests in lean manufacturing implementation and framing an administering model. Int. J. Lean Six Sigma 11(4), 797–820 (2020). https://doi.org/10.1108/IJLSS-11-2017-0131

    Article  Google Scholar 

  • Belokar, R.M., Kumar, V., Kharb, S.S.: An application of value stream mapping in automotive industry: a case study. Int. J. Innovative Technol. Exploring Eng. 1(2), 152–157 (2012)

    Google Scholar 

  • Boonsthonsatit, K. Jungthawan, S.: Lean supply chain management-based value stream mapping in a case of Thailand automotive industry. In: 4th International Conference on Advanced Logistics and Transport (ICALT), Valenciennes, pp. 65–69 (2015). https://doi.org/10.1109/ICAdLT.2015.7136593

  • Buer, S.-V., Strandhagen, J.O., Chan, F.T.S.: The link between Industry 4.0 and lean manufacturing: mapping current research and establishing a research agenda. Int. J. Prod. Res. 56(8), 2924–2940 (2018)

    Google Scholar 

  • Fox, J., Brammal, J., Yarlagadda, P.: Determination of the financial impact of machine downtime on the Australia Post large letters sorting process. In: Gudimetla, P., Yarlagadda, P. (eds.) Proceedings of the 9th Global Congress on Manufacturing and Management (GCMM2008), pp. 1–7 (2008)

    Google Scholar 

  • Ghobadian, A., Talavera, I., Bhattacharya, A., Kumar, V., Garza-Reyes, J.A., O’Regan, N.: Examining legitimatisation of additive manufacturing in the interplay between innovation, lean manufacturing and sustainability. Int. J. Prod. Econ. 219, 457–468 (2020). https://doi.org/10.1016/j.ijpe.2018.06.001

    Article  Google Scholar 

  • Goshime, Y., Kitaw, D., Jilcha, K.: Lean manufacturing as a vehicle for improving productivity and customer satisfaction: a literature review on metals and engineering industries. Int. J. Lean Six Sigma 10(2), 691–714 (2019)

    Article  Google Scholar 

  • Jorma, T., Tiirinki, H., Bloigu, R., Turkki, L.: Lean thinking in Finnish healthcare. Leadersh. Health Serv. 29(1), 9–36 (2016)

    Article  Google Scholar 

  • Kamble, S., Gunasekaran, A., Dhone, N.C.: Industry 4.0 and lean manufacturing practices for sustainable organisational performance in Indian manufacturing companies. Int. J. Prod. Res. 1–19 (2019). https://doi.org/10.1080/00207543.2019.1630772

  • Koskela, L.J.: Moving on - beyond lean thinking. Lean Constr. J. 1(1), 24–37 (2004)

    Google Scholar 

  • Kumar, N., Mathiyazhagan, K.: Manufacturing excellence in the Indian automobile industry through sustainable lean manufacturing: a case study. Int. J. Serv. Oper. Manage. 34(2), 180–196 (2019)

    Google Scholar 

  • Lacerda, A.P., Xambre, A.P., Alvelos, H.M.: Applying value stream mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry. Int. J. Prod. Res. 54(6), 1708–1720 (2016). https://doi.org/10.1080/00207543.2015.1055349

    Article  Google Scholar 

  • Braglia, M., Carmignani, G., Zammori, F.: A new value stream mapping approach for complex production systems. Int. J. Prod. Res. 44(18–19), 3929–3952 (2006). https://doi.org/10.1080/00207540600690545

    Article  MATH  Google Scholar 

  • Mady, S.A., Arqawi, S.M., Al-Shobaki, M.J., Abu-Naser, S.S.: Lean manufacturing dimensions and its relationship in promoting the improvement of production processes in industrial companies. Int. J. Emerg. Technol. 11(3), 881–896 (2020)

    Google Scholar 

  • Maunzagona, S.A., Telukdarie, A.: The Impact of Lean on the mining industry: a simulation evaluation approach. INCOSE Int. Symp. 27(1), 965–981 (2017). https://doi.org/10.1002/j.2334-5837.2017.00406.x

    Article  Google Scholar 

  • Mazzocato, P., Savage, C., Brommels, M., Aronsson, H., Thor, J.: Lean thinking in healthcare: a realist review of the literature. BMJ Qual. Saf. 19(5), 376–382 (2020)

    Article  Google Scholar 

  • Melton, T.: To lean or not to lean? (that is the question). Chem. Eng. 759, 34–37 (2004)

    Google Scholar 

  • Noto, G., Cosenz, F.: Introducing a strategic perspective in lean thinking applications through system dynamics modelling: the dynamic value stream map. Bus. Process. Manage. J. (2020). https://doi.org/10.1108/BPMJ-03-2020-0104

    Article  Google Scholar 

  • OSD: Küresel Değerlendirme Raporu [Global Assessment Report] (2020). http://www.osd.org.tr/osd-yayinlari/kuresel-otomotiv-sektoru-degerlendirme-raporlari/

  • Palak, P.S., Vivek, A.D., Hiren, R.K.: Value stream mapping: a case study of automotive industry. Int. J. Res. Eng. Technol. 03(01), 310–314 (2014). https://doi.org/10.15623/ijret.2014.0301055

    Article  Google Scholar 

  • Randhawa, J.S., Ahuja, I.S.: Evaluating impact of 5S implementation on business performance. Int. J. Product. Perform. Manage. 66(7), 948–978 (2017). https://doi.org/10.1108/IJPPM-08-2016-0154

    Article  Google Scholar 

  • Sanders, A., Elangeswaran, C., Wulfsberg, J.P.: Industry 4.0 implies lean manufacturing: research activities in Industry 4.0 function as enablers for lean manufacturing. J. Ind. Eng. Manage. (JIEM) 9(3), 811–833 (2016). https://doi.org/10.3926/jiem.1940

  • Saravanan, V., Nallusamy, S., Balaji, K.: Lead time reduction through execution of lean tool for productivity enhancement in small scale industries. Int. J. Eng. Res. Africa 34, 116–127 (2018). https://doi.org/10.4028/www.scientific.net/jera.34.116

  • Saravanan, V., Nallusamy, S., George, A.: Efficiency enhancement in a medium scale gearbox manufacturing company through different lean tools - a case study. Int. J. Eng. Res. Africa 34, 128–138. https://doi.org/10.4028/www.scientific.net/jera.34.128

  • Shan, H., Yuan, Y., Zhang, Y., Li, L., Wang, C.: Lean, simulation and optimization: the case of steering knuckle arm production line. In: 2018 IEEE International Conference on Industrial Engineering and Engineering Management (IEEM) (2018). https://doi.org/10.1109/ieem.2018.8607821

  • Sundar, R., Balaji, A.N., Kumar, R.M.S.: A review on lean manufacturing implementation techniques. Procedia Eng. 97, 1875–1885 (2014). https://doi.org/10.1016/j.proeng.2014.12.341

    Article  Google Scholar 

  • Veres, C., Marian, L., Moica, S., Al-Akel, K.: Case study concerning 5S method impact in an automotive company. Procedia Manuf. 22, 900–905 (2018)

    Article  Google Scholar 

  • Villarreal, B., Garza-Reyes, J.A., Kumar, V.: A lean thinking and simulation-based approach for the improvement of routing operations. Ind. Manag. Data Syst. 116(5), 903–925 (2016). https://doi.org/10.1108/IMDS-09-2015-0385

    Article  Google Scholar 

  • Womack, J.P., Jones, D.T.: Lean Thinking: Banish Waste and Create Wealth in Your Corporation. Simon & Schuster, New York (1996)

    Google Scholar 

  • Womack, J.P., Jones, D.T., Roos, D.: The Machine that Changed the World: The Story of Lean Production. HarperCollins Publishers, New York (1990)

    Google Scholar 

  • Yadav, G., Kumar, A., Luthra, S., Garza-Reyes, J.A., Kumar, V., Batista, L.: A framework to achieve sustainability in manufacturing organisations of developing economies using industry 4.0 technologies’ enablers. Comput. Ind. 122, 103280 (2020). https://doi.org/10.1016/j.compind.2020.103280

  • Yadav, G., Luthra, S., Huisingh, D., Mangla, S.K., Narkhede, B.E., Liu, Y.: Development of a lean manufacturing framework to enhance its adoption within manufacturing companies in developing economies. J. Cleaner Prod. 245, 118726 (2020)

    Google Scholar 

  • Yang, M.G., Hong, P., Modi, S.B.: Impact of lean manufacturing and environmental management on business performance: an empirical study of manufacturing firms. Int. J. Prod. Econ. 129(2), 251–261 (2011). https://doi.org/10.1016/j.ijpe.2010.10.017

    Article  Google Scholar 

Download references

Author information

Authors and Affiliations

Authors

Corresponding author

Correspondence to Hatice Camgöz-Akdağ .

Editor information

Editors and Affiliations

Rights and permissions

Reprints and permissions

Copyright information

© 2022 The Author(s), under exclusive license to Springer Nature Switzerland AG

About this paper

Check for updates. Verify currency and authenticity via CrossMark

Cite this paper

Aksar, O., Elgun, D., Beldek, T., Konyalıoğlu, A.K., Camgöz-Akdağ, H. (2022). An Integrated Value Stream Mapping and Simulation Approach for a Production Line: A Turkish Automotive Industry Case. In: Durakbasa, N.M., Gençyılmaz, M.G. (eds) Digitizing Production Systems. Lecture Notes in Mechanical Engineering. Springer, Cham. https://doi.org/10.1007/978-3-030-90421-0_30

Download citation

  • DOI: https://doi.org/10.1007/978-3-030-90421-0_30

  • Published:

  • Publisher Name: Springer, Cham

  • Print ISBN: 978-3-030-90420-3

  • Online ISBN: 978-3-030-90421-0

  • eBook Packages: EngineeringEngineering (R0)

Publish with us

Policies and ethics