A VSM and VSA methodology for performance assessment of complex product manufacturing processes: An industrial case study

This manuscript describes a Value Stream Mapping (VSM) based generic methodology that enables the visualisation, performance assessment (PA) and waste reduction (WR) in a Complex Products' Manufacturing Process (CPMP). The VSM, along with Kanban, enables modelling and implementing an order-driven or pull manufacturing process (MP) together with just-in-time material (or semi-finished items) arrivals. The methodology also incorporates a number arrays-based approach that enables a comprehensive Value Stream Analysis (VSA) when the value stream map (VSMap) becomes significantly large and complex. A case study has been performed in collaboration with a saw-blade sharpening machines' manufacturing firm to illustrate the use of the suggested VSM-based generic methodology and number arrays in VSA for PA of CPMPs. The calculated lead-time of the case study complex product (CP) is almost 323 days. All cycle times are smaller than takt time (TT) (i.e. 600 min). Copyright © 2017 Inderscience Enterprises Ltd.