Applying value stream mapping in an unbalanced production line: A case study of a Chinese food processing enterprise

Abstract

In recent decades, various manufacturing floors have followed lean initiatives. The focus of lean-initiative approaches is to improve efficiency by eliminating non-value-added activities. Value stream mapping (VSM) is one of the primary analytical tools used to identify waste and optimize production lines. Most of the existing literature concerning lean initiatives concentrates on industries such as traditional manufacturing, automotive, and service industries, with most empirical studies conducted in the USA and the UK. This study examines a Chinese agricultural food processing plant with very different processing capacities and processing times for each production process, and it identifies a feasible lean implementation process for this type of production system. The findings indicate that the optimal cycle time of each process in such cases cannot be determined simply based on the Takt time of the production line. The traditional value stream analysis technique should be modified when processing capacity and time are significantly different for each process.

Keywords:

• Lean manufacturing
• value stream mapping
• unbalanced processing capacity
• case study
• food processing industry

Acknowledgments

We acknowledge the invaluable contributions of the reviewers and the editor in improving our manuscript.

Additional information

Funding

This research is supported by the Social Science Foundation of Liaoning Province, China [grant number L18BJY038] and the fundamental research funds for the central universities of China [grant number 3132019023].

Notes on contributors

Qingqi Liu

Qingqi Liu is a PhD candidate at Logistics Research Institute, Dalian Maritime University, Dalian, China. Her research interests include lean manufacturing, value stream mapping and operation management. She has published research papers in the International Journal of Information and Management Sciences and the IEEE 29th Conference on Decision and Control proceedings.

Hualong Yang

Hualong Yang is a professor in Logistics Research Institute, Dalian Maritime University, Dalian, China. His research interest includes supply chain management and management science. He has published research papers in journals such as Operational Research, Transport, the Journal of Traffic & Transportation Engineering, and the Journal of Transportation Systems Engineering and Information Technology.

Yuchen Xin

Yuchen Xin is a PhD candidate at Logistics Research Institute, Dalian Maritime University, Dalian, China. His research interests include purchasing and supply chain management.