Process improvement using value stream mapping and lean methodology: a case study application in batch chemical process industry

Abstract

Abstract Intensifying competition in the global chemicals market is increasing the pressure on companies to adopt lean manufacturing and improve their operational efficiency to remain competitive. Companies operating in emerging economies are no exception. This study looks at the application of value stream mapping (VSM) in the production process of a batch chemical manufacturing company based in Indonesia. The application of value stream method is a multistep approach. A value stream scope is determined in the beginning, followed by a data collection step to construct a current state map. The current state is analysed to gain a deep understanding of how things currently operate and provides the foundation for the ideal future state of the production process. The production process is then redesigned following lean manufacturing principles, and the future state map is drawn. Analysis is then conducted to estimate the potential cost reduction from implementing the proposed future state. The results indicate a more efficient production system as shown by decreased production lead time and reduced production costs.