Novel approach to enhance the performance of production systems using lean tools

Value stream mapping (vsm) is a tool used for analyzing the current state of a production system and designing a future state by analyzing and improving the flow of material and reducing inefficiencies. however,aiming at improving performance without considering potential machine failures and other uncertainties in the production process may lead to an inaccurate future value stream map. the purpose of the present study is to introduce a novel approach that combines discrete event simulation,design of experiments (doe),and failure modes and effects analysis (fmea) to enhance the vsm processes. simulation modeling is utilized to evaluate production system performance and the severity of potential failure modes under several operational conditions. fmea and doe are then used to select the best systems enhancements which can be used to generate future map. the results of our approach show that failure modes can drastically affect the system performance if not taken into consideration,resulting in a non-representative future vsm. the proper selection of operational levels can reduce the severity of failures and at the same can provide high performance levels. © 2016 jordan journal of mechanical and industrial engineering.