Application of a concept development process to evaluate process layout designs using value stream mapping and simulation
Abstract: Purpose: We propose
and demonstrate a concept development process (CDP) as a framework to solve a
value stream mapping (VSM) related process layout design optimization problem.
Design/methodology/approach: A case study approach was used to
demonstrate the effectiveness of CDP framework in a portable fire extinguisher
manufacturing company. To facilitate the CDP application, we proposed the
system coupling level index (SCLI) and simulation to evaluate the process
layout design concepts.
Findings: As part of the CDP framework application, three process layout
design concepts - current layout (CL), express lane layout (ELL) and
independent zone layout (IZL) - were generated. Then, the SCLI excluded CL and
simulation selected IZL as the best concept. The simulation was also applied to
optimize the performance of IZL in terms of the number of pallets. Based on
this case study, we concluded that CDP framework worked well.
Research limitations/implications: The process layout design optimization
issue has not been well addressed in the VSM literature. We believe that this
paper initiated the relevant discussion by showing the feasibility of CDP as a
framework in this issue.
Practical implications: The CDP and SCLI are very practice-oriented
approaches in the sense that they do not require any complex analytical
knowledge.
Originality/value: We discussed a not well-addressed issue with a
systematic framework. In addition, the SCLI presented was also unique.
Keywords: concept development
process, lean manufacturing, simulation, value stream mapping, concept
selection
Author: Ki-Young Jeong, Don T Phillips
Journal Code: jptindustrigg110017
