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DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI

Year 2024, Volume: 29 Issue: 1, 19 - 36, 22.04.2024

Çağla Yurtseven Dilara Aydın Merve Ekici Senanur Aktepe Emine Eş Yürek Ali Yurdun Orbak

https://doi.org/10.17482/uumfd.1364297

Abstract

Bu çalışma, Bursa’da faaliyet gösteren otomotiv parçaları üreten bir firmanın ticari ayna ürün grubunda değer akış haritalama tekniği uygulayarak teslim süresini azaltmayı amaçlamaktadır. Bu doğrultuda, öncelikle ABC analizi ile ürün ailesi seçilmiş, istasyon çevrim sürelerini belirlemek amacıyla zaman etüdü yapılmış ve stoklar sayılmıştır. Mevcut durum haritası çizilerek stok ve taşımaların yoğun olduğu noktalar belirlenmiştir. Değer katan ve katmayan işlem adımlarının ayrıştırılması için NVA/VA analizleri yapılmış ve montaj hattı içerisindeki yürümeleri belirlemek için spagetti diyagramı çizilmiştir. Yapılan analizler sonucunda geliştirilen kaizen önerileri dikkate alınarak gelecek durum haritası çizilmiştir. Bu çalışma ile firmanın teslim süresi %52 kısalmıştır. Ayrıca, sistemin sınırsız imkânlara sahip olduğu ideal bir senaryo için ideal durum haritası çizilmiş, böyle bir durumda teslim süresinin %93 kısaltılabileceği gösterilmiştir.

Keywords

Değer akış haritalandırma Yalın üretim NVA/VA analizi Kaizen

References

  • 1. Aksar, O., Elgun, D., Beldek, T., Konyalıoğlu, A.K. ve Camgöz-Akdağ, H. (2022) An Integrated Value Stream Mapping and Simulation Approach for a Production Line: A Turkish Automotive Industry Case. Lecture Notes in Mechanical Engineering, Springer. doi.org/10.1007/978-3-030-90421-0_30
  • 2. Andrade, P.F., Pereira, V.G. ve Del Conte, E.G. (2016) Value stream mapping and lean simulation: a case study in automotive company, The International Journal of Advanced Manufacturing Technology, 85, 547-555. doi:10.1007/s00170-015-7972-7
  • 3. Aouag, H., Soltani, M. ve Mouss, M.D. (2020) Enhancement of value stream application process through using fuzzy DEMATEL and fuzzy QFD approaches: a case study considering economic and environmental perspectives, Journal of Modelling in Management, 16(3), 1002-1023. doi:10.1108/JM2-01-2020-0007
  • 4. Aydin, H. ve Cetin, C. (2021) Değer akışı haritalama ile süreçlerin iyileştirilmesi: Yalın organizasyonda bir vaka çalışması, Business and Economics Research Journal, 11(2), 445-459.
  • 5. Birgün, S., Gülen, K. G., ve Özkan, K. (2006) Yalın üretime geçiş sürecinde değer akışı haritalama tekniğinin kullanılması: İmalat sektöründe bir uygulama, İstanbul Ticaret Üniversitesi Fen Bilimleri Dergisi, 5(9), 47-59.
  • 6. Brown, A., Amundson, J ve Badurdeen, F. (2014) Sustainable value stream mapping (Sus-VSM) in different manufacturing system configurations: application case studies, Journal of Cleaner Production, 85, 164-179. doi:10.1016/j.jclepro.2014.05.101
  • 7. Dinis-Carvalho, J., Guimaraes, L., Sousa, R.M. ve Leao, C.P. (2019) Waste identification diagram and value stream mapping: A comparative analysis, International Journal of Lean Six Sigma, 10(3), 767-783. doi:10.1108/IJLSS-04-2017-0030
  • 8. Doğan, N.Ö. ve Kama, A. (2021) Tedarik zincirinde değer katmayan faaliyetlerin ortadan kaldırılması: İmalat sektöründe bir değer akış haritalama uygulaması, Niğde Ömer Halisdemir Üniversitesi Mühendislik Bilimleri Dergisi, 10(1), 091-099. doi: 10.28948/ngmuh.590637
  • 9. Guo, W., Jiang, P., Xu, L. ve Peng, G. (2019) Integration of value stream mapping with DMAIC for concurrent Lean-Kaizen: A case study on an air-conditioner assembly line, Advances in Mechanical Engineering, 11(2) 1–17. doi: 10.1177/1687814019827115
  • 10. Henrique, D.B., A.F., Filho, M.G. ve Esposto, K.F. (2016) A new value stream mapping approach for healthcare environments, Production Planning & Control, 27(1), 24-48. doi:10.1080/09537287.2015.1051159
  • 11. Jamil, N, Gholami, H., Saman, M.Z.M., Streimikiene, D., Sharif S. ve Zakuan N. (2020) DMAIC-based approach to sustainablevalue stream mapping: towards a sustainable manufacturing system, Economic Research-Ekonomska Istraživanja, 33:1, 331-360. doi: 10.1080/1331677X.2020.1715236
  • 12. Kahya E. (2011) İş Etüdü, Eskişehir Osmangazi Üniversitesi.
  • 13. Kholil, M., Suparno, A., Hasan, S.B.H. ve Aprilia, R. (2022) Lean approach for waste reduction in production line by integrating DMAIC, VSM and VALSAT method (Study : Assembling bracket manufacturing automotive industry), Journal of Intelligent Decision Support System, 5 (1), 37-43. doi.org/10.35335/idss.v5i1.30
  • 14. Lacerda, A. P., Xambre, A. R., ve Alvelos, H. M. (2016) Applying value stream mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry, International Journal of Production Research, 54(6), 1708-1720. doi:10.1080/00207543.2015.1055349
  • 15. Murugesan, V.S., Jauhar, S.K. ve Sequeira, A.H. (2022) Applying simulation in lean service to enhance the operational system in Indian postal service industry, Annals of Operations Research, 315, 993–1017. doi:10.1007/s10479-020-03920-1
  • 16. Qin, Y. ve Liu, H. (2022) Application of value stream mapping in e-commerce: A case study on an Amazon retailer, Sustainability, 14, 713. doi:10.3390/su14020713
  • 17. Rother, M. ve Shook, J. (1999) Learning to See: Value Stream Mapping to Create Value and Eliminate Muda, Lean Enterprise Institute, Cambridge.
  • 18. Salvador, R., Barros, M.V., dos Santos, G.E.T, van Mierlo, K.G, Piekarski, C.M. ve de Francisco, A.C. (2021) Towards a green and fast production system: Integrating life cycle assessment and value stream mapping for decision making, Environmental Impact Assesment Review, 87, 106519. doi:10.1016/j.eiar.2020.106519
  • 19. Salwin, M., Jacyna-Gołda, I., Ba´nka, M., Varanchuk, D. ve Gavina, A. (2021) Using value stream mapping to eliminate waste: A case study of a steel pipe manufacturer, Energies, 14, 3527. doi:10.3390/en14123527
  • 20. Sangwa N.R. ve Sangwan, K.S. (2023) Leanness assessment of a complex assembly line using integrated value stream mapping: a case study, The TQM Journal, 35(4), 1754-2731. doi:10.1108/TQM- 12-2021-0369
  • 21. Schmidtke, D., Heiser, U. ve Hinrichsen, O. (2014) A simulation-enhanced value stream mapping approach for optimisation of complex production environments, International Journal of Production Research, 52(20), 6146-6160. doi:10.1080/00207543.2014.917770
  • 22. Schoeman, Y., Oberholster, P. ve Somerset, V. (2021) Value stream mapping as a supporting management tool to identify the flow of industrial waste: A case study. Sustainability, 13, 91. doi:10.3390/su13010091
  • 23. Seth, D., Seth, N. ve Dhariwal, P. (2017) Application of value stream mapping (VSM) for lean and cycle time reduction in complex production environments: a case study, Production Planning & Control, 28(5), 398-419. doi:10.1080/09537287.2017.1300352
  • 24. Sevgili, A. ve Antmen, Z.F. (2019) Yalın üretim tekniklerinden değer akış haritalandırmanın bir metal işleme fabrikasında süreç iyileştirme amacıyla uygulanması, Avrupa Bilim ve Teknoloji Dergisi, 16, 219-228. doi:10.31590/ejosat.555940
  • 25. Shamsu Anuar, M. A. ve Mansor, M. A. (2022) Application of value stream mapping in the automotive industry: a case study, Journal of Modern Manufacturing Systems and Technology, 6(2), 34–41. doi:10.15282/jmmst.v6i2.8561
  • 26. Singh, B., Garg, S.K. ve Sharma, S.K. (2011) Value stream mapping: literature review and implications for Indian industry, International Journal of Advanced Manufacturing Technology, 53, 799-809. doi:10.1007/s00170-010-2860-7
  • 27. Singh, J., Singh, H., Singh, A. ve Singh, J. (2020) Managing industrial operations by lean thinking using value stream mapping and six sigma in manufacturing unit, Management Decision, 58(6), 1118-1148. doi:10.1108/MD-04-2017-0332
  • 28. Uygun, M., Taş, Ü. ve Pak, E. (2019) Değer akışı haritalandırma yöntemi ile verimliliğin arttırılması: Otomotiv sektöründe bir vaka çalışması, Verimlilik Dergisi, 3, 7-39.
  • 29. Vasconcelos Ferreira Lobo, C., Damasceno Calado, R. and Dalvo Pereira da Conceição, R. (2020) Evaluation of value stream mapping (VSM) applicability to the oil and gas chain processes, International Journal of Lean Six Sigma, 11(2), 309-330. doi:10.1108/IJLSS-05-2018-0049
  • 30. Verma, N. ve Sherma, V. (2019) A literature review on energy value stream mapping (EVSM), International Journal of Advanced Science and Technology, 27(1), 1-08.
  • 31. Zhu, X.Y., Zhang, H. ve Jiang, Z.G. (2020) Application of green-modified value stream mapping to integrate and implement lean and green practices: A case study, International Journal of Computer Integrated Manufacturing, 33(7), 716-731, doi:10.1080/0951192X.2019.1667028

An Application of Value Stream Mapping Technique in Automotive Industry

Year 2024, Volume: 29 Issue: 1, 19 - 36, 22.04.2024

Çağla Yurtseven Dilara Aydın Merve Ekici Senanur Aktepe Emine Eş Yürek Ali Yurdun Orbak

https://doi.org/10.17482/uumfd.1364297

Abstract

This study aims to reduce the delivery time by applying value stream mapping techniques in the commercial mirror product group of a company operating in Bursa, producing automotive parts. For this purpose, the product family was first selected by ABC analysis, a time study was conducted to determine station cycle times, and stocks were counted. The current situation map was drawn, and the points where stocks and transportations were intense were determined. NVA/VA analyses were performed to differentiate the value-added and non-value-added process steps, and a spaghetti diagram was drawn to determine the walks in the assembly line. The future situation map was drawn by considering the kaizen suggestions developed as a result of the analyses made. With this study, the company’s delivery time was shortened by 52%. In addition, an ideal situation map has been drawn for an ideal scenario where the system has unlimited possibilities, and it has been shown that the delivery time can be shortened by 93% in such a case.

Keywords

Value stream mapping Lean manufacturing NVA/VA analysis Kaizen

References

  • 1. Aksar, O., Elgun, D., Beldek, T., Konyalıoğlu, A.K. ve Camgöz-Akdağ, H. (2022) An Integrated Value Stream Mapping and Simulation Approach for a Production Line: A Turkish Automotive Industry Case. Lecture Notes in Mechanical Engineering, Springer. doi.org/10.1007/978-3-030-90421-0_30
  • 2. Andrade, P.F., Pereira, V.G. ve Del Conte, E.G. (2016) Value stream mapping and lean simulation: a case study in automotive company, The International Journal of Advanced Manufacturing Technology, 85, 547-555. doi:10.1007/s00170-015-7972-7
  • 3. Aouag, H., Soltani, M. ve Mouss, M.D. (2020) Enhancement of value stream application process through using fuzzy DEMATEL and fuzzy QFD approaches: a case study considering economic and environmental perspectives, Journal of Modelling in Management, 16(3), 1002-1023. doi:10.1108/JM2-01-2020-0007
  • 4. Aydin, H. ve Cetin, C. (2021) Değer akışı haritalama ile süreçlerin iyileştirilmesi: Yalın organizasyonda bir vaka çalışması, Business and Economics Research Journal, 11(2), 445-459.
  • 5. Birgün, S., Gülen, K. G., ve Özkan, K. (2006) Yalın üretime geçiş sürecinde değer akışı haritalama tekniğinin kullanılması: İmalat sektöründe bir uygulama, İstanbul Ticaret Üniversitesi Fen Bilimleri Dergisi, 5(9), 47-59.
  • 6. Brown, A., Amundson, J ve Badurdeen, F. (2014) Sustainable value stream mapping (Sus-VSM) in different manufacturing system configurations: application case studies, Journal of Cleaner Production, 85, 164-179. doi:10.1016/j.jclepro.2014.05.101
  • 7. Dinis-Carvalho, J., Guimaraes, L., Sousa, R.M. ve Leao, C.P. (2019) Waste identification diagram and value stream mapping: A comparative analysis, International Journal of Lean Six Sigma, 10(3), 767-783. doi:10.1108/IJLSS-04-2017-0030
  • 8. Doğan, N.Ö. ve Kama, A. (2021) Tedarik zincirinde değer katmayan faaliyetlerin ortadan kaldırılması: İmalat sektöründe bir değer akış haritalama uygulaması, Niğde Ömer Halisdemir Üniversitesi Mühendislik Bilimleri Dergisi, 10(1), 091-099. doi: 10.28948/ngmuh.590637
  • 9. Guo, W., Jiang, P., Xu, L. ve Peng, G. (2019) Integration of value stream mapping with DMAIC for concurrent Lean-Kaizen: A case study on an air-conditioner assembly line, Advances in Mechanical Engineering, 11(2) 1–17. doi: 10.1177/1687814019827115
  • 10. Henrique, D.B., A.F., Filho, M.G. ve Esposto, K.F. (2016) A new value stream mapping approach for healthcare environments, Production Planning & Control, 27(1), 24-48. doi:10.1080/09537287.2015.1051159
  • 11. Jamil, N, Gholami, H., Saman, M.Z.M., Streimikiene, D., Sharif S. ve Zakuan N. (2020) DMAIC-based approach to sustainablevalue stream mapping: towards a sustainable manufacturing system, Economic Research-Ekonomska Istraživanja, 33:1, 331-360. doi: 10.1080/1331677X.2020.1715236
  • 12. Kahya E. (2011) İş Etüdü, Eskişehir Osmangazi Üniversitesi.
  • 13. Kholil, M., Suparno, A., Hasan, S.B.H. ve Aprilia, R. (2022) Lean approach for waste reduction in production line by integrating DMAIC, VSM and VALSAT method (Study : Assembling bracket manufacturing automotive industry), Journal of Intelligent Decision Support System, 5 (1), 37-43. doi.org/10.35335/idss.v5i1.30
  • 14. Lacerda, A. P., Xambre, A. R., ve Alvelos, H. M. (2016) Applying value stream mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry, International Journal of Production Research, 54(6), 1708-1720. doi:10.1080/00207543.2015.1055349
  • 15. Murugesan, V.S., Jauhar, S.K. ve Sequeira, A.H. (2022) Applying simulation in lean service to enhance the operational system in Indian postal service industry, Annals of Operations Research, 315, 993–1017. doi:10.1007/s10479-020-03920-1
  • 16. Qin, Y. ve Liu, H. (2022) Application of value stream mapping in e-commerce: A case study on an Amazon retailer, Sustainability, 14, 713. doi:10.3390/su14020713
  • 17. Rother, M. ve Shook, J. (1999) Learning to See: Value Stream Mapping to Create Value and Eliminate Muda, Lean Enterprise Institute, Cambridge.
  • 18. Salvador, R., Barros, M.V., dos Santos, G.E.T, van Mierlo, K.G, Piekarski, C.M. ve de Francisco, A.C. (2021) Towards a green and fast production system: Integrating life cycle assessment and value stream mapping for decision making, Environmental Impact Assesment Review, 87, 106519. doi:10.1016/j.eiar.2020.106519
  • 19. Salwin, M., Jacyna-Gołda, I., Ba´nka, M., Varanchuk, D. ve Gavina, A. (2021) Using value stream mapping to eliminate waste: A case study of a steel pipe manufacturer, Energies, 14, 3527. doi:10.3390/en14123527
  • 20. Sangwa N.R. ve Sangwan, K.S. (2023) Leanness assessment of a complex assembly line using integrated value stream mapping: a case study, The TQM Journal, 35(4), 1754-2731. doi:10.1108/TQM- 12-2021-0369
  • 21. Schmidtke, D., Heiser, U. ve Hinrichsen, O. (2014) A simulation-enhanced value stream mapping approach for optimisation of complex production environments, International Journal of Production Research, 52(20), 6146-6160. doi:10.1080/00207543.2014.917770
  • 22. Schoeman, Y., Oberholster, P. ve Somerset, V. (2021) Value stream mapping as a supporting management tool to identify the flow of industrial waste: A case study. Sustainability, 13, 91. doi:10.3390/su13010091
  • 23. Seth, D., Seth, N. ve Dhariwal, P. (2017) Application of value stream mapping (VSM) for lean and cycle time reduction in complex production environments: a case study, Production Planning & Control, 28(5), 398-419. doi:10.1080/09537287.2017.1300352
  • 24. Sevgili, A. ve Antmen, Z.F. (2019) Yalın üretim tekniklerinden değer akış haritalandırmanın bir metal işleme fabrikasında süreç iyileştirme amacıyla uygulanması, Avrupa Bilim ve Teknoloji Dergisi, 16, 219-228. doi:10.31590/ejosat.555940
  • 25. Shamsu Anuar, M. A. ve Mansor, M. A. (2022) Application of value stream mapping in the automotive industry: a case study, Journal of Modern Manufacturing Systems and Technology, 6(2), 34–41. doi:10.15282/jmmst.v6i2.8561
  • 26. Singh, B., Garg, S.K. ve Sharma, S.K. (2011) Value stream mapping: literature review and implications for Indian industry, International Journal of Advanced Manufacturing Technology, 53, 799-809. doi:10.1007/s00170-010-2860-7
  • 27. Singh, J., Singh, H., Singh, A. ve Singh, J. (2020) Managing industrial operations by lean thinking using value stream mapping and six sigma in manufacturing unit, Management Decision, 58(6), 1118-1148. doi:10.1108/MD-04-2017-0332
  • 28. Uygun, M., Taş, Ü. ve Pak, E. (2019) Değer akışı haritalandırma yöntemi ile verimliliğin arttırılması: Otomotiv sektöründe bir vaka çalışması, Verimlilik Dergisi, 3, 7-39.
  • 29. Vasconcelos Ferreira Lobo, C., Damasceno Calado, R. and Dalvo Pereira da Conceição, R. (2020) Evaluation of value stream mapping (VSM) applicability to the oil and gas chain processes, International Journal of Lean Six Sigma, 11(2), 309-330. doi:10.1108/IJLSS-05-2018-0049
  • 30. Verma, N. ve Sherma, V. (2019) A literature review on energy value stream mapping (EVSM), International Journal of Advanced Science and Technology, 27(1), 1-08.
  • 31. Zhu, X.Y., Zhang, H. ve Jiang, Z.G. (2020) Application of green-modified value stream mapping to integrate and implement lean and green practices: A case study, International Journal of Computer Integrated Manufacturing, 33(7), 716-731, doi:10.1080/0951192X.2019.1667028
There are 31 citations in total.

Details

Primary Language Turkish
Subjects Industrial Engineering
Journal Section Research Articles
Authors

Çağla Yurtseven 0009-0007-5615-2109

Dilara Aydın This is me 0009-0002-3459-4516

Merve Ekici 0009-0003-8287-5619

Senanur Aktepe 0009-0007-1739-3604

Emine Eş Yürek 0000-0002-0871-3385

Ali Yurdun Orbak 0000-0002-4921-4275

Early Pub Date March 28, 2024
Publication Date April 22, 2024
Submission Date September 21, 2023
Acceptance Date February 22, 2024
Published in Issue Year 2024 Volume: 29 Issue: 1

Cite

APA Yurtseven, Ç., Aydın, D., Ekici, M., Aktepe, S., et al. (2024). DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi, 29(1), 19-36. https://doi.org/10.17482/uumfd.1364297
AMA Yurtseven Ç, Aydın D, Ekici M, Aktepe S, Eş Yürek E, Orbak AY. DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI. UUJFE. April 2024;29(1):19-36. doi:10.17482/uumfd.1364297
Chicago Yurtseven, Çağla, Dilara Aydın, Merve Ekici, Senanur Aktepe, Emine Eş Yürek, and Ali Yurdun Orbak. “DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI”. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi 29, no. 1 (April 2024): 19-36. https://doi.org/10.17482/uumfd.1364297.
EndNote Yurtseven Ç, Aydın D, Ekici M, Aktepe S, Eş Yürek E, Orbak AY (April 1, 2024) DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi 29 1 19–36.
IEEE Ç. Yurtseven, D. Aydın, M. Ekici, S. Aktepe, E. Eş Yürek, and A. Y. Orbak, “DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI”, UUJFE, vol. 29, no. 1, pp. 19–36, 2024, doi: 10.17482/uumfd.1364297.
ISNAD Yurtseven, Çağla et al. “DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI”. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi 29/1 (April 2024), 19-36. https://doi.org/10.17482/uumfd.1364297.
JAMA Yurtseven Ç, Aydın D, Ekici M, Aktepe S, Eş Yürek E, Orbak AY. DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI. UUJFE. 2024;29:19–36.
MLA Yurtseven, Çağla et al. “DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI”. Uludağ Üniversitesi Mühendislik Fakültesi Dergisi, vol. 29, no. 1, 2024, pp. 19-36, doi:10.17482/uumfd.1364297.
Vancouver Yurtseven Ç, Aydın D, Ekici M, Aktepe S, Eş Yürek E, Orbak AY. DEĞER AKIŞ HARİTALAMA TEKNİĞİNİN OTOMOTİV SEKTÖRÜNDE BİR UYGULAMASI. UUJFE. 2024;29(1):19-36.

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