Improving lead time in product development process of an agricultural machinery company through value-stream mapping (VSM)

Authors

  • Gilson José da Silva José Alberto da Silva Maria da Luz Ramires da Silva
  • Creusa Sayuri Tahara Amaral UNIARA - Universidade de Araraquara
  • Rodrigo Antônio Vicentini UNIARA - Universidade de Araraquara
  • Fábio Ferraz Junior UNIARA - Universidade de Araraquara

Keywords:

Lead time, Lean Manufacturing, Lean Office, Mapa do Fluxo de Valor, Processo de desenvolvimento de produto

Abstract

The constant search for process improvement requires a comprehensive knowledge of a company's resources, especially with regard to strategic processes for the organization, such as product development, which is directly related to technological changes and the needs of customers, which are becoming increasingly customized and difficult to meet. The value stream mapping method can help managers identify activities that cause losses in the process and may be effective in reducing the lead time in the product development process. Based on these assumptions, this work presents a case study on the application of value stream mapping in the product development process of an agricultural machinery company. The major sources of waste were identified and the process analyzed using value-stream mapping; proposals for changes were then made in consultation with the personnel involved in the projects. The application of the value-stream mapping method allowed the identification of waste in waiting time and in processing. We observed that if the improvement proposals are implemented, there may be a 41% reduction in the total lead time, which is a significant improvement for the process. Value-stream mapping allowed a simplified view of the process and facilitated the identification of waste and the understanding of process constraints, making value analysis more agile.

References

Antony, J., Snee, R., & Hoerl, R. (2017). Lean Six Sigma: yesterday, today and tomorrow, International Journal of Quality & Reliability Management, 34(7): 1073-1093.

Braglia, M., Carmignani, G., & Zammori, F. (2006). A new value stream mapping approach for complex production systems, International Journal of Production Research, 44(18/19): 3929-3952.

Ciarapica, F. E., Bevilacqua, M., & Mazzuto, G. (2016). Performance analysis of new product development projects: An approach based on value stream mapping, International Journal of Productivity and Performance Management, 65(2): 177-206.

Ciccullo, F., Pero, M., Caridi, M., Gosling, J., & Purvis, L. (2018). Integrating the environmental and social sustainability pillars into the lean and agile supply chain management paradigms: A literature review and future research directions, Journal of Cleaner Production, 172: 2336-2350.

Clark, K. B., & Wheelwright, S. C. (1993). Managing new product and process development: text and cases. New York. The Free Press.

Dobrota, D., & Dobrota, G. (2018). An innovative method in the regeneration of waste rubber and the sustainable development, Journal of Cleaner Production, 172: 3591-3599.

Dombrowski, U., & Karl, A. (2017). Lean Product Development for Small and Medium-Sized Suppliers, Procedia CIRP, 63: 615-620.

Gingnell, L. (2016). On Structuring and Practical Use of the Lean Product Development Concept: Based on case studies of industrial product development organizations. 273 p. Thesis (Doctor of Philosophy). KTH Royal Institute of Technology - Stockholm, Sweden.

Hardy-Vallee, B. (2012). The Cost of Bad Project Management. Business Journal. Disponível em: <http://news.gallup.com/businessjournal/152429/cost-bad-project-management.aspx> Acesso em: 20 abr. 2018.

Hines, P., Rick, N., & Esain, A. (1999). Value Stream Mapping. A distribution industry application. Benchmarking: Na International Journal, 6(1): 60-77.

Rafael Henao, William Sarache, Ivan Gomez Lean manufacturing and sustainable performance: Trends and future challenges, Journal of Cleaner Production 208 (2019) 99e116.

Holweg, M. (2007). The genealogy of lean production, Journal of Operations Management, 25: 420-437.

Hoppmann, J., Rebentisch, E., Dombrowskic, U., & Zahnc, T. (2015). A Framework for Organizing Lean Product Development, Engineering Management Journal, 23(1): 3-15.

Hu, D., Wang, Y., Huang, J., & Huang, H. (2017). How do different innovation forms mediate the relationship between environmental regulation and performance?, Journal of Cleaner Production, 161: 466-476.

Jasti, N. V. K., & Sharma, A. (2014). Lean manufacturing implementation using value stream mapping as a tool - A case study from auto components industry. International Journal of Lean Six Sigma, 5(1): 89-116.

Jeong, B. K., & Yoon, T. E. (2016). Improving It Process Management Through Value Stream Mapping Approach: A Case Study. Journal of Information Systems and Technology Management - Revista de Gestão da Tecnologia e Sistemas de Informação, 13(3), Set/Dez: 389-404 ISSN online: 1807-1775.

Jun, H-B., & Suh, H-W., (2008). A modeling framework for product development process considering its characteristics. IEEE Transactions on engineering management, 55(1).

Karam, A., Liviu, M., Cristina, V., & Radu, H. (2018). The contribution of lean manufacturing tools to changeover time decrease in the pharmaceutical industry. A SMED Project, Procedia Manufacturing, 22: 886–892.

Liker, J. K., & Morgan, J. M. (2006). The toyota way in services: The case of lean product development, Academy of Management Perspectives, 20(2): 5-20.

Marodin, G., Frank, A. G., Tortorella, G. L., & Netland, T. (2018). Lean product development and lean manufacturing: Testing moderation effects. International Journal of Production Economics, 203: 301–310. https://doi.org/10.1016/j.ijpe.2018.07.009.

Matt, D. T. T. (2014). Adaptation of the value stream mapping approach to the design of lean engineerto-order production systems: a case study, Journal of Manufacturing Technology Management, 25(3): 334-350.

Möldner, A. K., Garza-Reyes, J. A., & Kumar, V. (2018). Exploring lean manufacturing practices’ influence on process innovation performance. Journal of Business Research, (September). https://doi.org/10.1016/j.jbusres.2018.09.002

Ohno, T. (1988). The Toyota Production System: Beyond Large-Scale Production. Productivity Press, Portland.

Patil, V. M., & Bhatwadekar, S.G. (2015). Application of Value Stream Mapping for Lead Time Reduction and Inventory Control. International Journal of Engineering, Business and Enterprise Applications, February-May: 1-4.

Prates, C. C., & Bandeira, D. L. (2011). Aumento de eficiência por meio do mapeamento do fluxo de produção e aplicação do Índice de Rendimento Operacional Global no processo produtivo de uma empresa de componentes eletrônicos. Gestão e Produção, 18(4): 105-718.

Rauch, E., Dallasega, P., & Matt, D.T. (2017). The way from Lean Product Development (LPD) to Smart Product Development (SPD), Procedia CIRP, 50: 26-31.

Rother, M., & Shook, J. (2012). Aprendendo a enxergar: mapeando o fluxo de valor para agregar valor e eliminar o desperdício. São Paulo: Lean Institute Brasil.

Rozenfeld, H., Forcellini, F. A., Amaral, D. C., Toledo, J. C. D., Silva, S. L. D., Alliprandini, D. H. & Scalice, R. K. (2006). Gestão de desenvolvimento de produtos: uma referência para a melhoria do processo. São Paulo: Saraiva, 542p.

Sarache, W., & Gomez, I. (2019). Lean manufacturing and sustainable performance: Trends and future Challenges. Journal of Cleaner Production, 208: 99-116.

Schonberger, R.J. (2019). The disintegration of lean manufacturing and lean management. Business Horizons. doi.org/10.1016/j.bushor.2019.01.004

Shingo, S. (1981). A Study of the Toyota Production System from na Industrial Engineering Viewpoint. Japan Management Association, Tokyo.

Siyam, G. I., Wynn, D. C., & Clarkson, P. J. (2015). Review of Value and Lean in Complex Product Development, Journal Systems Engineering, 18(2): 192-207.

Synnes, E. L., & Welo, T. (2016). Enhancing Integrative Capabilities through Lean Product and Process Development, Procedia CIRP, 54: 221-226.

Suarez, T. M., Jung, C. F., & Caten, C. S. (2009). Adaptação e aplicação de um método de desenvolvimento de produtos em uma microempresa de manufatura de produtos decorativos, Revista P&D em Engenharia de Produção, 7(1): 37-63.

Tapping, D., & Shuker, T. (2003). Value Stream Management for the Lean Office: Eight Steps to Planning, Mapping and Sustaining Lean Improvements in Administrative Areas, Productivity Press, New York, NY.

Tapping, D., & Shuker, T. (2010). LEAN OFFICE: Gerenciamento do fluxo de valor para áreas administrativas – 8 passos para planejar, mapear e sustentar melhorias Lean nas áreas administrativas. 1.ed. São Paulo: Leopardo Editora.

Teichgraber, U. K., & Bucourt, M. (2012). Applying value stream mapping techniques to eliminate non-value-added waste for the procurement of endovascular stents, European Journal of Radiology, 81(1): 47-52.

Turrioni, J. B., & Mello, C. H. P. (2012). Metodologia de pesquisa em Engenharia de Produção: estratégias, métodos e técnicas para condução de pesquisas quantitativas e qualitativas. Itajubá: Unifei.

Ulrick, K. T., & EPPINGER, S. D. (2016). Product design and development, New York-NY: McGraw-Hill Education, 6ª Ed.

Verrier, B., Rose, B., & Caillaud, E. (2016). Lean and Green strategy: the Lean and Green House and maturity deployment model, Journal of Cleaner Production, 116: 150-156.

Womack, J. P, Jones, D. T., & Roos, D. (1990). The Machine That Changed the World. Rawson Associates, New York.

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

Womack, J. P. & Jones, D. T. (2003). Lean Thinking. Banish Waste and Create Wealth in Your Corporation, 2° ed., Free Press, New York, NY.

Downloads

Published

2020-10-13

Issue

Vol. 5 No. 4 (2020)

Section

Artigos

License

The Journal reserves the right to make normative, spelling and grammatical changes in the published article, aiming at maintaining the proper standard of the language, while respecting the personal style of the authors.
Author (s) are fully responsible for the published article. Journal of Lean Systems is not responsible for any violations of Copyright.
Journal of Lean Systems allows the author to retain the copyright of articles accepted for publication without restriction.
Plagiarism constitutes unethical behavior and is inconceivable. This journal reserves the right to use any methods of detecting plagiarism to analyze the submitted works.

This journal is licensed under a Creative Commons License.