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Journal of Industrial Engineeringand Management

JIEM, 2013 6(2): 456-476 Online ISSN: 2013-0953 Print ISSN: 2013-8423

tt!:""#$%#&i%&r'"10%3926"ie%532

Simulation guided value stream mapping and lean improvement:

A case study of a tubular machining facility

Wei Xia, Jiwen Sun*

East China Institute of Computer Technology, Dept. of Industrial Engineering and Management,

Shanghai JiaoTong University China!

ste"ensun#yahoo.com.cn*Corresponding author

$eceived% &ugust '()'&ccepted% January '()*

Abstract:

Purpose:This paper describes a typical Value stream mapping (VSM application enhanced by

the discrete e!ent simulation ("#S to a dedicated tubular manu$acturing process%

Design/Methodology/A pproach:VSM is prescribed as part o$ lean production port$olio o$ tools,

not only highlights process ine$$iciencies, transactional and communication mismatches, but

also guides impro!ement areas% Meanwhile, "#S is used to reduce uncertainty and create

consensus by !isuali&ing dynamic process !iews% 't is ser!ed as a complementary tool $or the

traditional VSM to pro!ide su$$icient usti$ication and )uanti$iable e!idence needed to con!ince

the lean approaches% simulation model is de!eloped to replicate the operation o$ an e+istingsystem, and that o$ a proposed system that modi$ies the e+isting design to incorporate lean

manu$acturing shop $loor principles%

indings: comprehensi!e model $or the tubular manu$acturing process is constructed, and

distincti!e scenarios are deri!ed to unco!er an optimal $uture state o$ the process% Various

simulation scenarios are de!eloped% The simulated results are ac)uired and in!estigated, and

they are well matched with the real production data%

!riginality/"alue:"#S is demonstrated as a guided tool to assist organi&ations with the decision

to implement lean approaches by )uanti$ying bene$its $rom applying the VSM% roadmap is

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http://www.jiem.org/mailto:[email protected]://www.omniascience.com/mailto:[email protected]://www.jiem.org/

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J&*rn+l & In#*tri+l En'ineerin' +n# M+n+'eent tt!:""#$%#&i%&r'"10%3926"ie%532

pro!ided to illustrate how the VSM is used to design a desired $uture state% The de!eloped

simulation scenarios mimic the beha!ior o$ the actual manu$acturing process in an intuiti!e

manner%

#ey$ords: !alue stream mapping, discrete e!ent simulation, capacity analysis, layout modi$ication, lean

manu$acturing, tubular machining

1. Introduction

.e *lti+te '&+l & le+n +n*+/t*rin' i t& re#*/e +te in +n!&er, inent&r, tie t&

+ret, t& e/&e i'l re!&nie t& /*t&er #e+n# ile !r*/in' *+lit !r*/t in

+ &t ei/ient +n# e/&n&i/+l +nner (&+/ J&ne, 1996)% It i ell n&n t+t eent!e & +te 'ener+ll &//*r (S*lli+n, M/&n+l# +n en, 2002), + lite# in .+le 1%

i*+li;in' te l& /re+te te +ilit t& ee ere, en, +n# & &t te in&r+ti&n +n#

!r*/t l& tr&*', +n# /&ne*entl re/&'ni;e +n# eliin+te te &*r/e & +te%

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+ll e t+e-&l#er% .ere i + nee# t& #eel&! + &re te+ti/ e+n t& el! '*i#e tee

le+n t&&l +n# +/tiitie% +l*e tre+ +!!in' (SM) i i'&r&*l /+!+le & *n#ert+in' ti

r&le% It n&t &nl i'li't !r&/e inei/ien/ie, tr+n+/ti&n+l +n# /&*ni/+ti&n i+t/e,

*t +l& '*i#e te i!r&eent +re+%

+l*e tre+ i + /&lle/ti&n & +ll +/ti&n (&t +l*e-+##e# +n# n&n-+l*e-+##e#) t+t +re

re*ire# t& rin' + !r*/t &r + !r*/t +il t+t *e te +e re&*r/e tr&*' te +in

l&, t+rtin' it r+ +teri+l +n# en#in' it te /*t&er (@il#er&*e .&ill, 2002)%

.e SM i #eine# + Ate i!le !r&/e & #ire/tl &erin' te l& & in&r+ti&n +n#

+teri+l + te n& &//*r, i*+ll *+ri;in' te, +n# ten enii&nin' + *t*re t+te

it */ etter !er&r+n/eB (J&ne &+/, 2000)% .e !ri+r &e/tie & te SM i

t& i#enti +ll in# & +te in te +l*e tre+ +n# t& t+e +/ti&n t& eliin+te tee (C&ter

S&&, 1999)% ile ree+r/er +e /re+te# n*er&* le+n t&&l t& &!tii;e in#ii#*+l

&!er+ti&n, &t & te +ll &rt in linin' +n# i*+li;in' te +teri+l +n# in&r+ti&n l&

tr&*'&*t te entire !r&/e (P+n++r, Deren&n J+e+r, 2003)% .e SM /re+te +

/&&n +i &r te !r&/e, t* +/ilit+te &re t&*'t*l #e/ii&n t& i!r&e it

(M/&n+l#, +n en Cente, 2002)% .i el! !l+n +n# lin le+n initi+tie tr&*'

te+ti/ #+t+ /+!t*re +n# +n+li% .e SM + eer'e# + te !reerre# + t&

i!leent le+n +!!r&+/e, &t ini#e +/ilitie +n# +t te *!!l /+in leel linin' t&e

+/ilitie (ine Ci/, 1997)% .i *ni*e +!!in' et +/ilit+te i*+li;+ti&n & te //le

tie, inent&r +t e+/ t+'e, *+n e&rt +n# in&r+ti&n l&% .e /*rrent &r A+ iB t+t*

i +!!e# t& /+!t*re + n+!&t & & tin' +re #&ne +n# ere te i!r&eent &l*ti&nlie, +n# te *t*re &r At& eB t+te +! i ten *ilt t& & & tin' &*l# e #&ne

/&ni#erin' !&tenti+l re*ireent%

?&r tr+#iti&n+l +n*+/t*rer, te rel*/t+n/e t& i!leent le+n t&&l +rie in/e teir

#itin/tie re*ireent re/*rrentl +e it +r# t& !re#i/t te '+in +'nit*#e +/iee#

#&in' &% It i +n en#e+&r +l& #*e t& te #ii/*lt in /+n'in' +!e/t in/l*#in' r+ +teri+l

!r&/*reent, inent&r +n+'eent, !r*/ti&n /&ntr&l, +n# +/ilit l+&*t% .ere&re,

+n+'eri+l #e/ii&n &ten rel &n te re!&rte# re*lt & &ter & +e i!leente#, &r

e*riti/ r*le & t* &n te e$!e/te# eneit% It i +l+ +n in*i/ient *tii/+ti&n, +n#

l+/ te *+ntii+le ei#en/e nee#e# t& /&nin/e te t& +#&!t le+n (ett Fin'lin',

2000)% ile in &e it*+ti&n te *t*re t+te +! /+n e e+l*+te# it rel+tiel et

e&rt, it i n&t + tr+i't&r+r# t& #& & in +n &ter% In 'ener+l, + /&!leent+r t&&l i

i!er+tie &r te SM t& *+nti te '+in #*rin' !l+nnin' +n# +eent t+'e%

SM + l&n' een iee# + + !+!er-+n#-!en/il e+n% It i liter+ll #r+te# +nerin'

!e/ii/ *eti&n &n i*e rel+te# t& ei/ien/ +n# &n te/ni/+l le+n t&&l i!leent+ti&n, +

lite# in .+le 2 (C&ter S&&, 1999)% In &e /+e, &eer, te *t*re t+te +! /+nn&te #ei'ne# &lel #&in' & in + r+n +nner% ?&r int+n/e, !re#i/tin' te inent&r l&

+n# leel i i!&ile it &nl t+ti/ #+t+% M&t /*rrentl re!&rte# SM +!!li/+ti&n #& n&t

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+!!e+r t& *tili;e i*l+ti&n% eel&!in' + *e*l i*l+ti&n el ten# t& e + len't +n#

tie /&n*in' t+, n&t ell +li'ne# it te rel+tiel *i/er //le tie% .ere&re,

i*l+ti&n + n&t e iee# + &rt te en#e+&r% +n e$teniel *e# !r&/e elin'

t&&l, &eer, i*l+ti&n i &ten *e# t& re#*/e *n/ert+int +n# /re+te /&nen*

i*+li;in' #n+i/ !r&/e ie &r + 'ien *t*re t+te% ##iti&n+ll, it el! e$!l&re

+ltern+tie 'ener+te# #ierent re!&ne t& t&e #ei'n *eti&n% Si*l+ti&n i /+!+le

& 'ener+tin' re&*r/e re*ireent +n# !er&r+n/e t+titi/ ilt re+inin' le$ile t&

!e/ii/ &r'+ni;+ti&n+l #et+il%

Level Questions

=+i/

1% +t i te t+t tieG

2% ill inie# '& e *ilt t& re!leni + *!er+ret, &r ill te e *ilt +n#

#ire/tl i!!e# t& /*t&erG

3% ere /+n /&ntin*&* l& !r&/ein' e *tili;e#G

4% I tere + nee# &r + *!er+ret !*ll te itin te +l*e tre+G

5% +t in'le !&int in te !r*/ti&n line ill e *e# t& /e#*le !r*/ti&nG

ei*n+

(Leveling Production)

6% & ill te !r*/ti&n e leele# +t te !+/e+er !r&/eG

7% +t in/reent & &r ill e /&nitentl rele+e# r& te !+/e+er !r&/eG

Kaizen (Improvement) 8% +t !r&/e i!r&eent ill e nee#e#G

.+le 2% ei'n *eti&n &r +l*e tre+ +!!in'

i/rete eent i*l+ti&n + een /&ni#ere# + &ne & te &t le$ile +n+lti/+l t&&l in

te +n*+/t*rin' te #ei'n +n# &!er+ti&n +re+% It i +''reiel *e# t& +n#le

*n/ert+int +n# /re+te #n+i/ ie & le+# tie +n# +/ine *tili;+ti&n% .i en+le

*+ntii/+ti&n & re*lt, +n# !r&i#e + !&iilit t& /&!+re te e$!e/te# !er&r+n/e

rel+tie t& t+t & te !reent &ne% It t* /+n e *e# t& +it &r'+ni;+ti&n it te #e/ii&n

t& i!leent te SM *+ntiin' eneit r& +!!lin' le+n !rin/i!le in teir !e/ii/

it*+ti&n% .ere i + i'nii/+nt n*er & !r+/titi&ner &riente# !+!er in ti +re+% .e

+&rit & te #e/rie te *e & i*l+ti&n t& +n+l;e e$itin' &r !l+nne# +n*+/t*rin'

te% @+n (1995) *e + i*l+ti&n el t& e+l*+te te !er&r+n/e & +n +*t&&tie

+n*+/t*rin' te + + *n/ti&n & #e+n#% Pr++ +n# @en (1995) #eel&! + i*l+ti&n

el & + le$ile +n*+/t*rin' te t& ineti'+te te &er+ll !er&r+n/e% el'++ +n#

Mill (1995) +n+l;e t& /ell #ei'n &r + +n*+/t*rin' +/ilit /&ni#erin' &!er+t&r +n#

+teri+l +n#lin' *tili;+ti&n +/t&r% @&, M&&n +n# F*n (1996) *e i*l+ti&n t& i#enti

!+r+eter t& i!r&e te !er&r+n/e +t + &t&r !r*/ti&n +/ilit% =i/+ (1996)

#e/rie i*l+ti&n in e+l*+tin' te !er&r+n/e & + te$tile +n*+/t*rin' *le it

&in' &rer% P+r, M+t&n +n# Miller (1998) #e/rie + i*l+ti&n +!!r&+/ *e# t& eri

t+t #+il tr&*'!*t re*ireent /+n e et +t + ne +el !l+nt, +n# it i *e# t&

#eterine te +$i* tr&*'!*t & te +/ilit +n# /+r+/teri;e# & te /&!&nent

*er e+e in ter & *+ntit l*/t*+ti&n +n# i#entiie# !&ile te &ttlene/%

S+n' +n# .+#i++ll+ (1998) *e + /&in+ti&n & i*l+ti&n +n# &!tii;+ti&n t& e+l*+te

te #ei'n & + /ell*l+r +n*+/t*rin' te% Per&n (2002) ineti'+te te i!+/t & +

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+rin' leel & te tr*/t*re #et+il in elin' + +n*+/t*rin' te% In +##iti&n t&

*in' i*l+ti&n t& #ire/tl +n+l;e +n# !re#i/t te !er&r+n/e, &e ree+r/er +e

*e# i*l+ti&n t& +li#+te +n+lti/+l el t+t +re in t*rn *e# &r t*#in' *n#erlin'

te% S*ri +n# eir+* (1997) *e i*l+ti&n t& +li#+te +n+lti/+l el +n# !re#i/t te

te !er&r+n/e &r + in'le +teri+l +n#lin' #ei/e /+e% .ere i n&t */ &r +e

een re!&rte# in /&nte$t t& +l*e tre+ t*#ie re'+r#in' +n*+/t*rin' +n# i*l+ti&n

+e# et&l&' (>i+n +n >+n#e'e, 2007)% ##iti&n+l +n# #et+ile# e$+!le & SM

i*l+ti&n +re +#l nee#e# in #ierent t!e & +/t*+l !r*/ti&n ettin'%

SM #ierenti+te itel r& /&nenti&n+l re/&r#in' +!!r&+/e% It el! i*+li;e //le tie,

inent&r *er +t intere#i+te t+ti&n, +n!&er #e!l&ent, *!tie, +n# te in&r+ti&n

l&% @&!+re# it te tr+#iti&n+l +n*+/t*rin' !r&/e i*l+ti&n +!!r&+/e, SM

!r&i#e eer+l +#+nt+'e% ?irtl, it i n&t &lel +!!in' te /*rrent t+t* *t +

te+ti/+l et&l&' t& *n#ert+n# te &le !r&/e, i#entiin' +n# #itin'*iin'

+l*e +##e# +n# n&n-+l*e +##e# +/tiitie% Se/&n#l, it &er + r&+#er +n# te leel

ie% .e tr+te'i/, t+/ti/+l +n# &!er+ti&n+l #e/ii&n +re erti/+ll /&&r#in+te#% >+tl, it n&t

&nl i'li't !r&/e inei/ien/ie, tr+n+/ti&n+l +n# /&*ni/+ti&n i+t/e, *t +l&

'*i#e te i!r&eent +re+% Si*l+ti&n /&ine# it te SM &er + i+le t&&l &r

e+l*+tin' te !&tenti+l leel & !r*/tiit '+in i/ /+n e +/iee# *in' le+n /&n/e!t%

Dener+ll, te SM !r&i#e + tr*/t*re# &r+t in i/ !r&/ee /+n e re#ei'ne#, +n#

i*l+ti&n &er + et&l&' &r e+l*+tin' e$!e/te# eneit r& !r&/e re#ei'n%

/+n e een, te SM i + ne/e+r *t n&t + *i/ient +!!r&+/ t& +n+l;e te i*e%

ei/ien/ie e+il +rie in/e it i + #eteriniti/ et +n# *e &nl #e/ri!tie +! t&

el !r*/ti&n &!er+ti&n% .ee in*i/ien/ie in/l*#e in/+!+ilit & elin' +n#

+ein' ee/t & +ri+ti&n, +in' *e & +ll ++il+le #+t+, +li#+tin' ee/t & !r&!&e#

ii/+ti&n e&re i!leent+ti&n, i#entiin' e$tr+ !&ile i!r&eent, +n# +ein'

inter+/ti&n eteen *te% .ere&re, n& e/+ni i ++il+le t& #itin'*i i te

!e/ii/+ti&n it /&nt+in ill !r*/e te #eire# te e+i&r &r +/iee !er&r+n/e

t+r'et% //&r#in'l, i*l+ti&n i tr&n'l re/&en#e# t& +it*ll +##re &!er+ti&n+l

i*e t+t te SM +ile# t& i#enti +n# /&*l# n&t re&le%

.e &e/tie & ti !+!er i t& #e&ntr+te te #i/rete eent i*l+ti&n + + '*i#e# t&&l t&

+it &r'+ni;+ti&n it te #e/ii&n t& i!leent le+n +!!r&+/e *+ntiin' eneit

r& +!!lin' te SM% r&+#+! i !r&i#e# t& ill*tr+te & te SM i *e# t& #ei'n +

#eire# *t*re t+te% i*l+ti&n el i #eel&!e# t& re!li/+te te &!er+ti&n & +n e$itin'

te, +n# t+t & + !r&!&e# te t+t iie te e$itin' #ei'n t& in/&r!&r+te le+n

+n*+/t*rin' &! l&&r !rin/i!le% *e t& te n+t*re & te #i/rete eent i*l+ti&n, te

#eel&!e# i*l+ti&n /en+ri& ii/ te e+i&r & te +/t*+l +n*+/t*rin' !r&/e in +nint*itie +nner% It i +l& e$!l&re# tr&*' +n in#*tri+l e$+!le & te i*l+ti&n

elin' i +!!lie#% .e re+in#er & te !+!er i &r'+ni;e# + &ll&: Se/ti&n 2 'ie +n

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&erie & te et&l&'% Se/ti&n 3 e$!l&re te i*l+ti&n !r&/e *e# in *!!&rt &

/&ntr*/tin' +n# ineti'+tin' /*rrent +n# *t*re t+te% ?in+ll, /&n/l*i&n +n# *t*re

#ire/ti&n +re !r&i#e# in Se/ti&n 4%

2. Overview of methodology

i/rete eent i*l+ti&n !r&i#e + +l*+le t&&l &r te SM i!leent+ti&n% ?irt, te

e$e/*ti&n & + #i/rete eent i*l+ti&n el i +e# &n +n eent &r +/tiit t+t &//*r in

te +n*+/t*rin' !r&/e% Ce/ent #eel&!ent & te +ni+ti&n +n# #+t+ inter+/e &

i*l+ti&n &t+re +ll& SM t& e 'r+!i/+ll !reente# +n# inte'r+te# int& te e$itin'

/&!+n +n*+/t*rin' in&r+ti&n te% Se/&n#l, i*l+ti&n el te t&/+ti/

n+t*re inerent in te +n*+/t*rin' !r&/e en te i'l i'nii/+nt +n# intrini/ +ri+ti&n

+n# #n+i/ e+i&r i /+r+/teri;e#% Si*l+ti&n '*i#e# SM i tere&re + n+t*r+l e$teni&n

& e$itin' SM +!!li/+ti&n% et&l&' & #i/rete eent i*l+ti&n '*i#e# +l*e tre+

+!!in' *in' iGrafx&t+re i !r&!&e#% /&!reenie i*l+ti&n el i #eel&!e# t&

re!li/+te te &!er+ti&n & +n e$itin' te, +n# te !r&!&e# ne te it + iie#

#ei'n t& in/&r!&r+te le+n +n*+/t*rin' &! l&&r !rin/i!le%

te+ti/ +!!r&+/ i &ll&e# t& #eel&! te SM +n# &!tii;e te +/ilit% ?irt, +t+

/&lle/ti&n +n# +li#+ti&n i *n#ert+en t& &r te /*rrent t+te /en+ri& +n# eri te

!r&!&e# el% .en, /+!+/it /+l/*l+ti&n +n# l+&*t ii/+ti&n &r te *t*re t+te +!

+re ineti'+te#% ?in+ll, te i*l+ti&n el +n# +ri&* /en+ri& +re 'ener+te# +n# te

*t*re t+te +! i !r&!&e#% et+il & te et&l&' +re + &ll&%

Initi+ll, te r&*tin' tie #+t+ +re re/eie# r& te /&!+n% .e &*t!*t & /+l/*l+ti&n +n#

/&!*ter el +re &nl + '& + te in!*t, +n# in+//*r+te #+t+ '*+r+ntee e+nin'le

&*t!*t% .ere&re, /&ni#er+le tie i !ent &n te &! l&&r &erin' te &le

+n*+/t*rin' !r&/e t& /&nir te /&niten/ & te tie #+t+ it te re!&rte# &ne% .e

!r*/t +re #ierenti+te# len't, #i+eter, +n# +teri+l% it +ll te !+rt n*er, it i

i!&ile t& /l&/ tie &r e+/ &ne% &eer, te +/inin' &!er+ti&n re*ire# t& ini

te !r*/t +re iil+r% .e +li#+ti&n i &nl /+rrie# &*t &r te !+rt t+t +re +/t*+ll l&in'

tr&*' te +n*+/t*rin' !r&/e% .e re/&r#e# r&*tin' tie & +r&*n# 20 t!e & !r*/t

+re /&!+re# it te #+t+ !r&i#e#% Oer+ll, te re!&rte# #+t+ i +//*r+te en&*' &r *rter

i*l+ti&n%

.& e+l*+te te !&tenti+l '+in, + #et+ile# i*l+ti&n el i /&ntr*/te# *in' iGrafx

&t+re% It &er +ri&* !r&/e +n+li &l*ti&n t+t el! #&/*ent, +n+l;e +n# i!r&e

teir &!er+ti&n% S!e/ii/+ll, it i *e# t& /re+te +l*e tre+ +!, l& /+rt, t& ere + +

/&!reenie el /&ntr*/t&r t& r*n +n*+/t*rin' !r&/e i*l+ti&n% .ere +re t&-

&l# !*r!&e in *in' ti &t+re% ?irt, te SM /+n e #r+n +//&r#in' t& +ri&* t+n#+r#

+!e +n# line tle ++il+le r& it t&&l+r +n# '+ller% Se/&n#, te Aein# /reenB

+l'&rit ill e #e/rie# /re+tin' + !r&/e el, #i!l+in' + + l& /+rt% ter

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+in' #r+n te !r&/e te! +n# l&, &ne /+n enter #+t+ +&/i+te# it e+/ &e/t t&

+r it #itin/tie !r&!ertie% In 'ener+l, *il#in' + i*l+ti&n el +n# !r&/e *in'

iGrafxin&le eer+l +i/ +/tiitie: (1) @re+te + !r&/e el #i+'r+ *in' #e!+rtent,

+!e, +n# /&nne/t&r lineH (2) e/rie te e+i&r & e+/ +/tiitH (3) @&ntr*/t te

i*l+ti&n enir&nent te !r&/e lie in tr&*' te /en+ri&H +n# (4) E$e/*te + i*l+ti&n

+n# +n+l;e te re*lt% In 'ener+l, + !r&/e el i #eel&!e# i/ /&nit & +/tiitie,

re&*r/e, +n# *ine r*le t+t '&ern !r&/e e+i&r% .r+n+/ti&n +rrie +t te in!*t &

+n +/tiit r& + #+t+ 'ener+t&r, +n# re&*r/e + !er&r + t+ &n e+/ tr+n+/ti&n%

en te t+ i /&!lete#, te tr+n+/ti&n &*t!*t ere + te in!*t & te ne$t +/tiit

tr&*' + /&nne/t&r line% .e &t+re '+ter t+titi/ #*rin' i*l+ti&n &n re&*r/e

*tili;+ti&n, //le tie, /&t, /+!+/it, +n# &ter !re-#eine# +n# /*t&i;+le t+titi/%

erii/+ti&n i + i'l ne/e+r te! t+t en*re te i*l+ti&n el *i/ientl re!reent

+n# +#e*+tel re!li/+te te re+l te% .i in/l*#e /+re*l tr+/e t*#ie, #et+ile#

+ni+ti&n t& eri !r&!er te e+i&r, +n# + reie & te el e+i&r i+ +ni+ti&n

+n# n*eri/+l &*t!*t% *e t& te n+t*re & #i/rete eent i*l+ti&n, te #eel&!e# i*l+ti&n

ii/ te e+i&r & te +/t*+l +n*+/t*rin' !r&/e in +n int*itie +nner% .i ii/

e+i&r en+le te +n+'eent +n# &!er+t&r t& *n#ert+n# te l&'i/ it /l+rit% Sin/e it

i + l+r'e el it +n t!e & in!*t entitie, /&nir+ti&n i re*ire# t+t eer in# &

entitie i tr+/e# +n# te /&rre!&n#in' el l&'i/ i /e/e# t& '*+r+ntee te re*ire#

e*en/e i &ll&e#% .e e$!li/it re!reent+ti&n & +ri&* entitie +n# te e*en/e & eent

&//*rrin' in te t*e +n*+/t*rin' !r&/e +e te i*l+ti&n el &t /le+r +n# e+ile$ten#e# t& +//&*nt &r &ter +!e/t & te !r&/e% Seer+l e+t*re +re *e# te

i*l+ti&n !r&/e, in/l*#in' +ri+le r*n tie +/t*+ll +i'ne# +e# &n te +/ine +n#

&!er+t&rB e$!erien/eH +ri+le et*! tie +i'ne# +e# &n te !rei&* +n# ne$t !+rt

/+r+/teriti/, */ + !+rt t!e, i#t, !e/ii/+ti&nH r*le +i'ne# &r e*en/in' & +t

&r /enter, +e# &n inii;in' et*! +n# &ter +/t&rH +n# r*le +i'ne# &r ele/tin'

r& + lit & !ri&riti;e# & +e# &n #*e #+te, l+/, /&t%

/t*+l #+t+ i ++il+le r& te +n*+/t*rin' e$e/*ti&n in&r+ti&n te% +t+et +re

r& te irt t& *+rter & 2011% It +ll& /&!+rin' te i*l+ti&n re*lt it te +/t*+l

!r*/ti&n tr&*'!*t t& tet it /re#iilit% .e el i ri'&r&*l +li#+te# +n# i &*n# t&

+it*ll re!reent te +/t*+l +n*+/t*rin' !r&/e% It i *ite +tiie# t+t te n*eri/+l

&*t!*t r& te i*l+ti&n +re +ll itin te r+n'e & te +/t*+l #+t+% .e tr&*'!*t +n#

&r-in-!r&'re (IP) leel r& te el ell +t/ it te +/t*+l !r*/ti&n #+t+% .i

+//*r+/ 'ie te +n+'eent /&ni#en/e n&t &nl in te #ei'n+te# i*l+ti&n &t+re +n#

te #eel&!e# +l'&rit in i*l+ti&n elin', *t +l& teir !&tenti+l + + #e/ii&n-+in'

t&&l%

.e /*rrent +n# *t*re t+te /+!+/it /en+ri& +re +/*ire# e$!erientin' it #ierent

+/ine /&in+ti&n +n# it !+ttern% .ee /en+ri& +re !ri+ril #eel&!e# +//&r#in' t&

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te&reti/+l +n# !r+/ti/+l /&ni#er+ti&n% .e te&reti/+l &ne /&n/ern +&*t +te+ti/+l

!+r+eter, */ + +/ine /+!+/it, +/ine /&ni'*r+ti&n (+##iti&n &r *tr+/ti&n &

/ert+in +/ine t!e, +/ine /&in+ti&n), it !+ttern% .e !ri+r '&+l i t& +l+n/e

tr&*'!*t, IP +n# !r*/ti&n le+# tie% .ee /&ntr+int +//&*nt &r re+l /&ni#er+ti&n &

te +/ine /&ni'*r+ti&n, &rin' tie ++il+ilit +n# !erii&n% ?&r e$+!le, te

+/ine /&ni'*r+ti&n /&ni#er te +##iti&n & + tir# ill in te /*rrent !+e +n# + tir#

'r&*! & l+te (t& t&'eter) in te ne+r *t*re, */ + &ne-&l#-&ne-ne-Mill, &ne-ne-Mill,

t&-&l#-&ne-ne-Mill, t&-&l#-Mill, +n# teir /&in+ti&n it te tir# 'r&*! & l+te,

re!e/tiel% //&r#in' t& in#ii#*+l /+!+/it, e+/ +/ine i re!&nile t& &r it

#ierent it !+ttern% It i +n&ter /&ntr+int &r #eel&!in' /en+ri&% ile !r+/ti/+l

/&ni#er+ti&n in/l*#e te +/ine *#'et, &! l&&r l+&*t +n# !+/e, /&ne&r /&nne/ti&n,

l+&r it +n# &li#+, +/inin' /+!+ilit & /ert+in +/ine + ell%

i/ /+n e ere# + re+liti/ /+n#i#+te +re ele/te#% Seer+l *nre+liti/ +n# iil+r

/+n#i#+te +re t* n&t /&en% Onl &e it+l +n# #itin/tie /en+ri& +re ele/te# t& +r

te #ierent &rin' /&n#iti&n% .e in+l te! i t& i*l+te te !&tenti+l *t*re t+te

/en+ri& +n# *lti+tel ele/t +n &!ti+l *t*re t+te /en+ri& &r te *t*re t+te +!%

3. nhancing value stream mapping with simulation

.& +e te +li#it & te !r&!&e# et, + re+l +n*+/t*rin' !r&/e i t&r&*'l

+n+l;e# +n# + !&ile le+n &l*ti&n i !reente#% .i +!!li/+ti&n i i!leente# itin +

#&eti/ +n*+/t*rin' +/ilit% S!e/ii/+ll, te !l+nt i #e&te# t& t**l+r +/inin'% .e

&r'+ni;+ti&nB i#entit i !r&te/te# +n# t&e rel+te# in&r+ti&n +ll n&t e rele+e#, & +

!+rt & te in&r+ti&n i +ltere#% In te re+in#er & te !+!er, it ill e i!l reerre# t& +

te /&!+n%

.e +/tiit in te /&!le$ +n*+/t*rin' !r&/e i '&erne# *+n #ei'ne# &!er+ti&n+l

r*le% .e #n+i/ & ti !r&/e +re /+r+/teri;e# +n/r&n&* &//*rren/e & #i/rete

eent */ + te +rri+l &r #e!+rt*re & + &, &r te initi+ti&n +n# /&!leti&n & +

#ei'n+te# +n*+/t*rin' t+% .ere&re, te #i/rete eent i*l+ti&n /+n e ell *e# in

ti /+e t*#% lt&*' te +&r #i+#+nt+'e & ti i*l+ti&n +!!r&+/ + &!!&e# t& +n

&r#in+r +n+lti/+l +!!r&+/ i it /*er&e /&t +n# /&!*t+ti&n intenit% .e i*l+ti&n

i &re +//*r+te in/e it i n&t #eel&!e# +e# &n + +n +*!ti&n + +n+lti/+l

!r&/e#*re% .e SM irtl i#entiie +l*e +##e# +n# n&n-+l*e +##e# +/tiitie, i/ +e

te i*l+ti&n &/* &n &e e +/tiitie +n# */ e+ier t& /&n#*/t%

.e /&!+n t+rte# t& *ll +n*+/t*re in 2008, +n# it n& !r*/e +!!r&$i+tel 1600

*nit & t*e !er &nt it +ll in# & !e/ii/+ti&n% E+/ in+l !r*/t /&nit & +n &*ter

t*e +n# +n inner t*e, i/ +re /+lle# /+rrier +n# l&+#in' t*e, re!e/tiel% .ere&re, t&

e!+r+te !r*/ti&n line +re #ei'ne#, &ne &r /+rrier +n# te &ter &r l&+#in' t*e% t te

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en# & te t**l+r +n*+/t*rin' !r&/e, te l&+#in' t*e i +n*+ll inerte# int& te /+rrier

t& &r te in+l +el% It i ten !+/e# +n# ent &*t t& te +!!r&!ri+te l&/+ti&n% .e

/&!+n +n*+/t*re +ll te /+rrier in-&*e ilt +ri/+te &nl 50 & it l&+#in' t*e

+n# &*t&*r/e te re+in#er t& l&/+l *!!lier% .e +/ilit l+&*t +n# it +&/i+te#

+n*+/t*rin' !r&/e +re ill*tr+te# in ?i'*re 1% .e e +n*+/t*rin' !r&/e#*re &r te

/+rrier +re r& +in', tr&*' l+tin' +n# illin', t& +el +n# !+/in'% .e e*en/e

&r te l&+#in' t*e i r& l+er /*ttin' t& el#in'% .ere +re t& !+r+llel l+te line, +n#

e+/ &ne i e*i!!e# it t& i#enti/+l l+te% //&r#in' t& te te/ni/+l !e/ii/+ti&n, te

/+rrier i e*enti+ll l&e# r& te irt l+te &r +/inin' &ne en# +n# te e+, ten

tr&*' te e/&n# l+te &r te &ter en# it&*t + e+%

?i'*re 1% @*rrent +/ilit l+&*t !l+n

It i n&t tr+i't&r+r# t& +ner te i!+/t i*e it te SM +l&ne% Seer+l +/t&r nee#

t& e eri&*l /&ni#ere#, in/l*#in' te n*er & #ierent !r*/t +ilie !r*/e#,

+ri&* !r&/ein' tie +n# et*! tie &r e+/ &!er+ti&n+l te!, #itin/t it !+ttern &r

e+/ &r t+ti&n, +n# eri+l-!+r+llel !r&/ein' !+t tr&*' te !r*/ti&n line + ell%

.ee +/t&r t&'eter /re+te + /&!le$it t+t /+nn&t e +##ree# *in' te SM +l&ne%

/&!reenie i*l+ti&n el i *ilt t& t&r&*'l *n#ert+n# te +n*+/t*rin'

!r&/e, + ill*tr+te# in ?i'*re 2% .e i*l+ti&n el in/&r!&r+te eer+l #itin/tie

e+t*re% ?&r e$+!le, e+/ &r t+ti&n !r&/ee !+rt +e# &n it in#ii#*+l //le tie &r

e+/ !+rt n*er% Set*! tie +re +*t&+ti/+ll in/l*#e# int& te el en !+rt n*er

/+n'e% .ie +ri+ilit i +l& /&ni#ere# it #ei'n+te# n&r+l #itri*ti&n, in/l*#in'

+ri+ilit & +rri+l r+te, //le tie, et*! tie, +n# &e tie% ##iti&n+ll, it !+ttern

+re +//&*nte# t& e /&nitent it te re+l &r /e#*le (in/l*#in' e$+/t re+ tie) +n#

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te ++il+ilit & in#ii#*+l &rer% ?*rter&re, M+/ine *!tie +n# *n/e#*le# +/ine

re+#&n +re in/&r!&r+te#%

?i'*re 2% iGrafxi*l+ti&n el

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Si*l+ti&n +re /+rrie# &*t *in' +/t*+l !r*/ti&n &r#er & te irt t& *+rter & 2011

l&in' tr&*' te !r*/ti&n te% Or#er +re e# int& te el tr&*' te inter-+rri+l

'ener+t&r &n te t&! & te el +n# &ne /+n /&&e ti r+te +t i/ te +rrie% t e+/

&r t+ti&n, te /+rrier +/inin' tr+n+/ti&n i !r&/ee# +//&r#in' t& it in#ii#*+l //le

tie it +!!r&!ri+te +ri+ilit% I + !+rt n*er /+n'e, te el +//&*nt &r te et*!

tie% .e #i+&n# +!e re!reent #e/ii&n l&'i/, +n# te +re *e# t& r&*te te /+rrier t&

te #eire# &r t+ti&n +//&r#in' t& te !re#eine# /&ntr+int%

= *in' ti el, n*er&* +t-iK /en+ri& +re tete# +n# &ne i #eee# &!ti+l%

.ee /en+ri& +re #itin/tie in +ri&* e+t*re, in/l*#in' +##iti&n &r *tr+/ti&n &

+/ine, +l+n/in' & &r it, *in' #ierent +rri+l r+te% .e i*l+te# re*lt +re *e#

t& *n#ert+n# +//**l+ti&n & IP e&re +n# +ter e+/ +/ine, t& /&!+re te +/ine

ei/ien/, t& !r&!erl +//&*nt &r +ri+ilit% It i *tili;e# t& +l+n/e tr&*'!*t, IP +n#

!r*/ti&n le+# tie% Oer+ll, te i*l+ti&n el i ere# + + 'ener+l t&&l &r *t*re it,

!r*/t i$ +n# e$!+ni&n #e/ii&n%

3.1. !urrent state "#$

.e /*rrent t+te SM i /&n/*rrentl #r+te# ile ineti'+tin' te i*l+ti&n el +e#

&n te eriie# #+t+, + &n in ?i'*re 3% .&e +ll &$e re!reent te +/inin' !r&/e,

+n# te n*er ini#e te &$ i te n*er & +/ine +t e+/ !r&/e% l&, e+/ !r&/e

+ + #+t+ &$ el&, i/ /&nt+in te !r&/e //le tie, +/ine ++il+ilit, te n*er

& it, +n# te /+n'e&er tie% It i /le+r t+t te /*rrent t+te SM & +ri&* it+l

#et+il lie &r t+ti&n //le tie, *!tie +n# tie ++il+le in e+/ it% .e tri+n'le it +

letter AIB ini#e re!reent te inent&r !ile# *! +t +ri&* t+'e% Eenti+ll, it *+ri;e

in&r+ti&n +&*t +/t*+l +l*e-+##e# tie +n# t&t+l !r*/ti&n le+# tie% .e i*+li;+ti&n &

#ierent tie +n# &ter +/t*+l in#in' 'ie +n +/t*+l tri''er +n# &er + /+llen'e &r

*t*re i!r&eent% It &*l# e n&te# t+t te !r&/ein' +n# et*! tie +re /&lle/te#

ilt t+in' +n# re/&r#in' &n te &! l&&r +n# #i/*in' it te +n*+/t*rin'

*!eri&r +n# &!er+t&r +t e+/ &rt+ti&n%

=+e# &n te #e+n# &re/+t, + eel /e#*le i 'ener+te# &r e+/ tre+ & te !r&/e

t& !* &r#er tr&*' !r*/ti&n% ##iti&n+ll, + *!eri&r i in /+r'e t& /&ntr&l !r*/ti&n,

+e #+il +#*tent t& &le +n !&ile !r&le, +n# *lill +n *r'ent &r#er%

te+ti/ !r&/e#*re &r te SM i &ll&e# e&re te i*l+ti&n, ere + erie &

tr*/t*re# *eti&n i +nere#% .i +ll& &ne t& eni+'e +n i#e+l *t*re t+te +! t+t

ill el! eliin+te &r +t le+t re#*/e #ierent t!e & +te in te /*rrent +n*+/t*rin'

te%

.e +n*+/t*rin' /+!+/it i !rei&*l n&t ell *n#ert&, +n# it /+*e + l+r'e +n#

*n&r'+ni;e# IP ini#e te +/ilit% Ori'in+ll, t& ill +re *e# &r te /+rrier +n*+/t*rin'

!r&/e% tir# &re !&er*l +n# ei/ient ill i intr*/e# re/entl t& tren'ten +n#

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+l+n/e te /+!+/it% *eti&n i r+ie# eter t& eliin+te &ne, &t &r neiter & te &l#

ill% l&, + !r*/ti&n in/re+in'l it t& te /&!+n, tere i + nee# &r + /le+r

*n#ert+n#in' & it /*rrent +n# *t*re t+te !r*/ti&n /+!+ilitie% .e rel+ti&ni! eteen

tr&*'!*t, IP +n# !r*/ti&n le+# tie +re e$!l&re#, +n# n*er&* /&in+ti&n &

!r*/ti&n line, te n*er & +/ine +n# it !+ttern +re /&ni#ere#%

?i'*re 3% @*rrent t+te SM

ter r*nnin' + *ltit*#e & i*l+ti&n, t& /en+ri& +re ele/te# + te &!ti+l *t*re

t+te% .e /+!+/it +n+li & &ne-&l#-&ne-ne ill /en+ri& i #e/rie# in .+le 3% .e

#et+ile# +/ine !er&r+n/e /+n e reerre# t& te .+le 1 in te !!en#i$% I te /&!+n

ret+in it /*rrent tr*/t*re & *t t& l+te line, it i /&n/l*#e# t+t te &ne-&l#-&ne-ne

ill /en+ri& !r&i#e te et &er+ll !er&r+n/e%

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en /&!+rin' tr&*'!*t, IP +n# !r*/ti&n le+# tie, te i#e+l it*+ti&n t& +l+n/e

tree +/t&r i it + een-in*te +rri+l r+te% it ti !+/e, tr&*'!*t i 2543 *nit !er

&nt, ile IP i rel+tiel l& +t 74 *nit +n# !r*/ti&n le+# tie +er+'e +&*t 15%1

&*r, i%e% 844 in*te & +it tie !l* 60 in*te & +/t*+l !r*/ti&n tie% .i ren#er +

#r+ti/ i!r&eent &er te /*rrent t+te ere &ntl tr&*'!*t i +&*t 1600 *nit,

IP i &er 700 *nit +n# !r*/ti&n le+# tie i +!!r&$i+tel 26 &*r%

?i'*re 4% IP % tr&*'!*t & &ne &l# &ne ne ill /en+ri&

n&ter /en+ri& i e$!e/te# te /&!+n t& e+l*+te i te !&tenti+l +##iti&n & + tir# et

& l+te, in/e te l+te +re n& te !r&/e &ttlene/% .& *n#ert+n# te ee/t ti ne

l+te line &*l# +e &n te tr&*'!*t +n# +l& & +n ill &*l# e ne/e+r t&

!r&!erl +l+n/e te line, te /+!+/it +n+li i ineti'+te#, + &*tline# in .+le 4% .e

#et+ile# +/ine !er&r+n/e /+n e reerre# t& te .+le 2 in te !!en#i$%

%arameters #aw Lathe 1 Lathe 2 $ill &ssem'ly(%ac)ing

@/le tie (in) 3%0 17%1 13%0 18%1 6%0

Set*! tie (in) 1%5 3%0 3%0 1%4 0%0

.&t+l tie (in) 4%5 20%1 16%0 19%6 6%0

Sit 2 3 3 3 3

=re+ tie (in) 60 60 60 60 60

O!er+t&r 1 1 1 1 4

N*er & M+/ine 1 3 3 3 1

S/r+! r+te 0%0 2%3 2%3 1%7 0%0

@+!+/it 181 165 193 176 204

.+le 4% @+!+/it +n+li & tree >+te +n# tree Mill /en+ri&

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.e +$i* tr&*'!*t e$!e/te# &r + 22-#+ !eri i +!!r&$i+tel 3750 *nit, +

ill*tr+te# in ?i'*re 5% &eer, en leer+'in' tr&*'!*t it IP +n# !r*/ti&n le+#

tie, te &!ti+l it*+ti&n i it + ie-+n#-+-+l-in*te +rri+l r+te, le+in' tr&*'!*t &

3293 *nit !er &nt% t ti +rri+l r+te, IP i +n+'e+le +t 75 *nit +n# !r*/ti&n le+#

tie +er+'e +&*t 16%4 &*r, i%e% 927 in*te & +it tie !l* 60 in*te & +/t*+l

!r*/ti&n tie% .i tr&*'!*t & 3300 *nit !er &nt &er + 30 in/re+e &er t+t &

te &ne-&l#-&ne-ne ill /en+ri&%

?i'*re 5% IP % tr&*'!*t & tree l+te +n# tree ill /en+ri&

3.2. *uture state "#$

.e el i /&n/retel *e# t& +ner te *eti&n +&*t te /+!+/it +n# /+!+ilitie & te

/&!+n +n# ill el! '*i#e #e/ii&n &r *t*re e$!+ni&n% Oer+ll, te el i +n e$/ellent

t&&l +n# i *e# intelli'entl, ill !r&i#e +ri&* *e*l ini't +&*t te +n*+/t*rin'

!r&/e% It i e*i+lent t& te A+/t&r ini#e + /&!*terB it le$iilit in + &t+re

enir&nent% ?*rter&re, te l+&*t re/&en#+ti&n +re +//&!+nie# it te /+!+/it+n+li *in' le+n +n*+/t*rin' !rin/i!le, #et+il /+n e reerre# t& in te !!en#i$% .e

+re ell t+en te +n*+/t*rin' en'ineer +n# +n+'eent, +n# te +e +lre+# een

+//e!te# +n# i!leente#% .ee /+n'e ill en*re + etter +teri+l l&, e!e/i+ll in te

+el"!+/in' +re+% l&, te ill +e tie +n# !+/e% te #e+n# i e$!e/te# t& rie,

+teri+l l& ill !l+ +n in/re+in'l i!&rt+nt r&le, +n# tee ii/+ti&n ill el! +n#le

te i'er !r*/ti&n &l*e &re ei/ientl% .ere i +l& + +retin' +#+nt+'e r& ein'

+le t& eet /*t&er #e+n# itin &rter le+# tie%

D*i#e# tee i*l+te# re*lt +n# iie# l+&*t !l+n &n in ?i'*re 6, te *t*re t+te

SM i +l& /&ntr*/te#, + ill*tr+te# in ?i'*re 7% Pri&r t& +##in' + ne ill, te t&t+l

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!r*/ti&n r+te i +!!r&$i+tel 1600 !er &nt &n +er+'e% it te +##iti&n & te ne

ill, it i +le t& /&&rt+l +/iee &ntl tr&*'!*t & 2500 *nit &r 22 &rin' #+,

&t + +n# +el"!+/in' &r t& it + #+, l+te +n# ill &r tree it + #+%

.e /&!+n ill &nl nee# &ne & it &l# ill +n# it ne ill t& re+/ ti !r*/ti&n leel%

ltern+tiel, i +n +##iti&n+l l+te line i /e#*le# t& in/&r!&r+te, te tir# ill ill nee# t&

&!er+te in &r#er t& +n#le te &l*e l&in' r& te tree l+te line, &r te !*r!&e &

leelin' te !r*/ti&n% it te +##iti&n & + tir# l+te line, te t&t+l !r*/ti&n r+te ill e

+/iee# t& + leel & +!!r&$i+tel 3300 *nit, ere te &le &nt i 22 &rin' #+,

+ &r t& it + #+, l+te, ill +n# +el"!+/in' &r tree it + #+% It

+//&!lie +n in/re+e & 29%5 &er te /*rrent t+te /en+ri&%

?i'*re 6% >+&*t ii/+ti&n & +el"!+/in' +re+

.i in#*tri+l +!!li/+ti&n + #e&ntr+te# t+t te #i/rete eent i*l+ti&n /+n e + *e*l!+rt & te SM% lt&*' it i n&t !r&!&in' t+t i*l+ti&n +l+ e *tili;e# it te SM, it

&r +n inte'r+l !+rt & te le+n +!!r&+/% S!e/ii/+ll, + &*n# in ti /+e, en tere i

!r*/t /&!le$it i/ le+# t& #ieren/e in !r&/ein' +n# et*! tie +/r& !r*/t

+ri+nt, !+r+llel !r&/ein' line +n# #ierent n*er & it *e# +/r& + !r*/ti&n line,

i*l+ti&n !r&i#e i!&rt+nt in&r+ti&n t& /&!leent t+t &t+ine# r& *t*re t+te

+!!in'% ?*rter&re, i*l+ti&n +/ilit+te !r&/e i*+li;+ti&n, /re+tin' + +re# /&nen*

+&*t te !r&/e +n# ere i!r&eent &l*ti&n /+n e +#e%

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?i'*re 7% ?*t*re t+te SM

.i #i/rete eent i*l+ti&n '*i#e# SM r+e&r in/l*#e &t te +n+'eri+l +n# te

&!er+ti&n+l +!e/t & te +n*+/t*rin' !r&/e% Onl ten /+n +n+'eent &e e&n#

te tr+#iti&n+l t+ti/ !er&r+n/e +n+li% .i i*l+ti&n '*i#e# SM +ll& te +n+'eent

t& #ierenti+te eteen +l*e +##e# +n# n&n-+l*e +##e# +/tiitie, +n# it + te !&tenti+l t&

e + tr+te'i/ #e/ii&n +in' t&&l &r !r&/e re#ei'n +n# /&ntin*&* i!r&eent% it te

#et+ile# in&r+ti&n &t+ine# r& te i*l+ti&n '*i#e# SM, it i !&ile t& #eterine i

&er+ll /&t +in' &r in/re+e# reen*e /+n e +#e it +##iti&n+l /+!it+l inetent%

Me+nile, t& te &!er+ti&n+l t+, i!leentin' i*l+ti&n '*i#e# SM /+n e +r &re

/&nenient, !&nt+ne&*, inter+/tie, +n# tr+i't&r+r# t+n te tr+#iti&n+l !+!er-+n#-!en/il

+e# SM% Si*l+ti&n /en+ri& !r&i#e te le$iilit re*ire# te SM t& /&!e it te

/+n'e in /&in+ti&n +n# !er*t+ti&n &ten en/&*ntere# in ti +n*+/t*rin' !r&/e%

It i /riti/+l t& reeer t+t te SM +n# rel+te# le+n +!!r&+/e re*ire + +/t&r l&&r

&/*, +n# te /&!*ter i*l+ti&n +n+li &*l# n&t #etr+/t r& ti !il&&!, n&r

&*l# it *tit*te &r &r i!e#e te l& & in&r+ti&n r& te +/t&r l&&r% C+ter, te

i*l+ti&n &*l# e + '*i#e# t&&l t+t &nl en+n/e *t n&t re!l+/e te SM &erin'

+n# *+ntiin' l&n' ter ee/t t+t +re n&t re+#il +!!+rent &n te l&&r, +re ++il+le r&

tr+#iti&n+l +n*+/t*rin' in&r+ti&n te, &r +re t&& e$!enie &r tie /&n*in' t&

e$!erient it &n te l&&r% l& &ne &*l# e+r in in# t+t +n eneit & te SM +n#

rel+te# le+n +!!r&+/e /+nn&t e *+ntiie# it i*l+ti&n elin'% Intillin' !r&!er

&r'+ni;+ti&n+l +l*e, &r'+ni;+ti&n le+rnin' +n# e!l&ee e!&erent te, /&ntin*&*

i!r&eent !r&'r+, +n# ettin' *! + /&nitent &r'+ni;+ti&n tr*/t*re + ell +

+n+'eent in&r+ti&n te, +re eenti+l +n# +n#+t&r eleent & le+n te% I

tee +n+'eent !rin/i!le +re n&t *ll +#&!te# +l&n' it Ai*l+ti&n-+e# SMB, te SM

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ill n&t +/iee +ll te eneit t+t /&*l# n&t e *+ntiie# +n# it !er&r+n/e /&*l# e

ineri&r t& te te it re!l+/e#%

+. !onclusions and future study

.e SM i + ne/e+r *t n&t + *i/ient +!!r&+/ t& +n+l;e !r*/ti&n te i*e%ei/ien/ie &ten +rie #*e t& it #eteriniti/ n+t*re, i/ +e te tr+#iti&n+l SM n&t

+l+ tr+i't&r+r# t& #e/rie te /*rrent t+te & + +n*+/t*rin' !r&/e +n# #ei'n +

#eire# *t*re t+te% i/rete eent i*l+ti&n i ten *tili;e# t& en+n/e *t n&t re!l+/e te

SM i*+li;in' etter #n+i/ e+t*re & te *t*re t+te e&re i!leent+ti&n% ierent

i*l+ti&n /en+ri& +re #eel&!e# &erin' te +/t*+l !r&/ein' tie & +/tiitie in te

+n*+/t*rin' !r&/e +n# ten /+r+/teri;in' teir +ri+ti&n t+titi/+l #itri*ti&n%

r&+#+! i &ere# t& & & te SM +n# te #i/rete eent i*l+ti&n +re /&ine#

t&'eter t& !r&i#e ne/e+r in&r+ti&n &r i!r&eent #e/ii&n !r&le en/&*ntere# in

le+n +n*+/t*rin' i!leent+ti&n%

ile +!!lin' te SM &e !re/+*ti&n &*l# e &ere#% Sin/e it 'ie +n ill*tr+tie

ie & te !r&/e +t +n !+rti/*l+r int+nt & tie, it + /+!t*re te r&n' re!reent+ti&n

+t t+t !+rti/*l+r int+n/e, i/ + ile+# #e/ii&n-+er% M&re&er, te SM &nl

*''et +&*t te +re+ & i!r&eent% It #&e n&t #i/* +n r*le & t* t& +/iee te

i!r&eent% e!ite te in+#e*+/, it i + re+ll !&er*l t&&l% It lin !e&!le, t&&l, etri/

+n# een re!&rtin' re*ireent t& +/iee le+n +n*+/t*rin'% It !r&i#e /le+r +n# /&n/ie

/&*ni/+ti&n eteen +n+'eent +n# &! l&&r te+ +&*t le+n e$!e/t+ti&n, +l&n'

it +/t*+l +teri+l +n# in&r+ti&n l&% en/e, it +ll& *n#ert+n#in' +n# /&ntin*&*l

i!r&in' te *n#ert+n#in' & le+n /&n/e!t%

.ere +re &e interetin' e$teni&n &r *t*re &r:

?irtl, *t*re t*#ie &*l# inte'r+te te +!!r&+/ it e/&n&i/ e+*re t& e$!re &t

+l*e-+##e# +n# n&n-+l*e-+##e# /&t *t+ine# tr&*' te !r&/e% .e !ri+r '&+l &

te #eel&!e# i*l+ti&n el i t& +l+n/e tr&*'!*t, IP +n# !r*/ti&n le+# tie%

ierent &e/tie, */ + /&t inii;+ti&n, +/ine ++il+ilit +$ii;+ti&n, &*l# e

e$!l&re# t& e$+ine te !er&r+n/e & te i*l+ti&n el%

Se/&n#l, + &re *t+nti+te i*l+ti&n el &*l# e /&ntr*/te# t& in/&r!&r+te &re

!r+/ti/+l i*e rel+$in' &e +*!ti&n% Si*l+ti&n el +re #eel&!e# &erin'

te +/t*+l !r&/ein' tie & +/tiitie in te !r&/e +n# ten /+r+/teri;in' teir +ri+ti&n

t+titi/+l #itri*ti&n% &eer, tee tie +re re/&r#e# + !&rti&n & te

+n*+/t*re# !r*/t t!e% It i +*e# t+t te tie #+t+ & te ret !r*/t ill +t/

it te +/t*+l &!er+ti&n tie% M&re !r*/t t!e &*l# e in!*t t& te i*l+ti&n el &r*rter +li#+ti&n% ?*rter&re, te iel# r+te i +*e# t& e 100 it n& #ee/t +!!ene#

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eiter #*rin' &r +t te en# & te +n*+/t*rin' !r&/e, i/ &*l# +e + +ir i!+/t &n

te i*l+te# re*lt%

n +##iti&n+l iel# &r *t*re ree+r/ i't e e$ten#in' te /*rrent +n*+/t*rin' !r&/e t&

e+l*+te te &le *!!l /+in% One &*l# in# t+t it i ne/e+r t& +! &t inter-

/&!+n +n# intr+-/&!+n +l*e-+##e# tre+% It i + +r &re &/*e# +n# /&ntin'ent

ie & te +l*e-+##e# !r&/e%

&c)nowledgements

.e +*t&r 're+tl +/n&le#'e te e#it&r +n# te reieer &r teir +l*+le /&ent +n#

*''eti&n t+t +e le# t& + *t+nti+l i!r&eent & te !+!er%

,eferences

=+rer, C%@% (1994)% .e #ei'n & le+n +n*+/t*rin' te *in' tie +e# +n+li%

International Journal of Operations and Production Management, 14, 86-96%

tt!:""#$%#&i%&r'"10%1108"01443579410068666

=i/+, %P% (1996)% Per&r+n/e & + +n*+/t*rin' *le it &in' &rer% IIE

ransactions, 28, 723-733%

@+n, ?%.%S% (1995)%

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>i+n, F%% +n >+n#e'e, % (2007)% n+lin' te ee/t & >e+n +n*+/t*rin' *in' +

+l*e tre+ +!!in'-+e# i*l+ti&n 'ener+t&r% International Journal of Production

#esearc$, 45(13), 3037-3058% tt!:""#$%#&i%&r'"10%1080"00207540600791590

M/&n+l#, .%, +n en, E%M% Cente, %?%, (2002)% e+n Enter!rie Intit*te, M++/*ett%

S+n', J%S%, .+#i++ll+, P%C% (1998)% M*lti/riteri+ #ei'n +n# /&ntr&l & + /ell*l+r

+n*+/t*rin' te tr&*' i*l+ti&n +n# &!tii;+ti&n% International Journal of

Production #esearc$, 36, 1515-1528% tt!:""#$%#&i%&r'"10%1080"002075498193147

S*lli+n, %D%, M/&n+l#, .%, +n en, E%M% (2002)% E*i!ent re!l+/eent #e/ii&n +n#

le+n +n*+/t*rin'% #obotics and %omputer/Integrated Manufacturing, 18, 255-265%

tt!:""#$%#&i%&r'"10%1016"S0736-5845(02)00016-9

S*ri, C%, eir+*, C%, (1997)% Per&r+n/e +n+li & le$ile +n*+/t*rin' te it +

in'le #i/rete +teri+l-+n#lin' #ei/e% International Journal of 0lexible Manufacturing

!"stems&9, 223-249% tt!:""#$%#&i%&r'"10%1023":1007901028906

el'++, P%S%, Mill, C%D%J% (1995)%

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&ppendi-

ter te initi+l +n+li & te !l+nt +/ilit, t& !r&le+ti/ +re+ +re i#entiie#: *n/ert+in

/+!+/itie +n# inei/ient el +n# P+/in' +re+%

?&r te *n/ert+in /+!+/itie, te #et+ile# +/ine !er&r+n/e & &ne-&l#-&ne-ne ill/en+ri& /+n e 'ener+li;e#, + &n in .+le 1% Dien te /*rrent tr*/t*re & *t t&

l+te line, ti /en+ri& !r&i#e# te et &er+ll !er&r+n/e /&ni#erin' /+!+/it +l+n/e%

+te1 1320 15 475 89%0

>+te1= 1316 16 529 89%0

&r t+ti&n 2636 31 502 89%0

>+te2 1320 2 55 75%0

>+te2= 1315 2 53 76%0

&r t+ti&n 2635 4 54 75%5

Mill-Ne 2027 11 222 75%0

Mill 523 8%8 607 72%0

&r t+ti&n 2550 19%8 280 74%6

el"P+/in' 2543 19 5

.&t+l 74 844

.+le 1% M+/ine !er&r+n/e & &ne &l# &ne ne ill /en+ri&

Sin/e te l+te +re n& te !r&/e &ttlene/, +n&ter /en+ri& i e+l*+te# t& /&ni#er te

!er&r+n/e & !&tenti+l intr*/ti&n & + tir# et & l+te% .+t i tree-l+te-tree-ill

/en+ri&% .i el! *n#ert+n# te ee/t + ne l+te line &*l# +e &n te tr&*'!*t +n#

+l& & +n ill &*l# e ne/e+r t& !r&!erl +l+n/e te line% .e #et+ile# +/ine

!er&r+n/e & ti /en+ri& /+n e een r& .+le 2% In ti /+e, + /&ntin*e t& &r

*t t& it ile +ll &ter &r t+ti&n &r tree%

.e +el +n# !+/in' +re+ + een re#ei'ne# + !er te ne l+&*t &n in ?i'*re 6,

i/ #r++ti/+ll re#*/e te tie #*rin' te ei-inie# t**l+r tr+n!&rt+ti&n in

+/inin'%

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$achine hroughput /unit0 WI% /unit0 Wait ime /min0 tiliation

S+ 3360 0%6 4%6 65%0

>+te1 1120 9%7 359 75%0

>+te1= 1120 8%3 305 76%0

>+te1@ 1120 9 331 77%0

&r t+ti&n 3360 27 332 76%0>+te2 1120 1 41 64%0

>+te2= 1120 1 26 63%0

>+te2@ 1120 1 48 64%0

&r t+ti&n 3360 3 38 63%7

Mill-Ne 2280 22 416 87%0

Mill 505 12 997 84%0

Mill= 509 5 417 65%0

&r t+ti&n 3294 39 489 83%9

el"P+/in' 3293 5 63

.&t+l 75 927

.+le 2% M+/ine !er&r+n/e & tree l+te tree ill /en+ri&

J&*rn+l & In#*tri+l En'ineerin' +n# M+n+'eent, 2013 (%ie%&r')

rti/le /&ntent +re !r&i#e# &n + ttri*ti&n-N&n @&er/i+l 3%0 @re+tie /&&n li/ene% Ce+#er +re +ll&e# t& /&!, #itri*te

+n# /&*ni/+te +rti/le /&ntent, !r&i#e# te +*t&r +n# J&*rn+l & In#*tri+l En'ineerin' +n# M+n+'eent n+e +re in/l*#e#%It *t n&t e *e# &r /&er/i+l !*r!&e% .& ee te /&!lete li/ene /&ntent, !le+e iit

tt!:""/re+tie/&&n%&r'"li/ene"-n/"3%0"%
http://www.intangiblecapital.org/http://www.intangiblecapital.org/http://www.intangiblecapital.org/http://www.intangiblecapital.org/

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