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Value stream designing a factory

New standard for the manufacturing sector could be viable in industries untouched by lean
: Erlach, Klaus; Sheehan, Erin

Industrial engineer : IE 48 (2016), Nr.1, S.31-36
ISSN: 1085-1259
ISSN: 1542-894X
Fraunhofer IPA ()
factory planning; Produktionsoptimierung; Factory Layout; Wertstrom; Lean manufacturing; lean production; Value Stream Mapping (VSM); Wertstromdesign (WSD)

The design of optimal production procedures is a factory planner's most important and central duty. This undertaking must overcome various obstacles, such as factory-specific restrictions and conflicting manufacturing objectives. Additionally, as soon as an ideal state is nearly reached, the goal posts are shifted again, as customer wishes, production technologies and legal requirements are subject to constant change. As a result, the never-ending task of optimizing production and its requirements on factory design are ever present in all factory operations.
For the last 15 years, following the release of Learning to See by Mike Rother and John Shook, companies have used the value stream method to improve the transparency of their processes and highlight production system waste for potential improvement projects. While mapping alone may provide some benefit, Fraunhofer IPA in Stuttgart, Germany, has taken this practice to the next Ievel, using value stream maps to methodically redesign production systems to their lean ideal state.
This article details the effectiveness of the value stream method for production system design, describing the procedures and guidelines that have been tried and tested in numerous industries. This method has proved effective at increasing the competitive edge of manufacturing sites, even in high cost countries like Germany, Austria, Switzerland, the United Kingdom and the United States.