Enhancing Rice Milling Efficiency through Lean-Based Process Improvement Using Value Stream Mapping
DOI:
https://doi.org/10.63746/njtd.v22i3.3340Keywords:
Lean tools, Manufacturing value chain, Wastes, Value Stream MappingAbstract
Variability within a synchronous flow line due to process inefficiency and waste generation may jeopardise the production throughput. The study seeks to use a lean-based improvement process to enhance an existing rice processing and milling facility in Otukpo, Benue state, Nigeria, using a simulated model of Value Stream Mapping (VSM). The study objective is to appraise the state of the operations at various points in the manufacturing value chain using the existing state value stream map (ESVSM) and seek improvement where there are inefficiencies. The IGrafx software was employed in formulating and modeling the ESVSM, showing the process steps and identifying areas of waste on the processing line. Line balancing charts are drawn through simulation to identify imbalances in the process flow to optimise work flow at various workstations and increase process efficiency. Further analyses were conducted using the Monte Carlo sensitivity analysis on Python programmes to analyse the relationship between metrics such as productivity, quality, cost, and on-time delivery vis-à-vis other metrics such as cycle time, lead time, inventory, work-in-progress, finished goods, value-added time, production efficiency, defect rate, and on-time delivery. The results of the new state value stream map (NSVSM) present a reduction in the following areas: lead time by 61.24%, cycle time by 41.14%, raw material movement time by 64.44% and non-value added time by 90.08% with improvements in work in progress by 60.04% and overall process efficiency by 28.68% following the implementation of the lean tool. In addition, the simulation results show potential improvement in the overall production efficiency by 73.2%. This study may assist process industry in achieving process improvement. The novelty of this study lies in the fact that the development of a lean-based process for process improvement in rice milling operation using value stream mapping and simulation approach has not been sufficiently reported by the existing literature.
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