Value stream mapping and WIP and lead time optimization for a make-to-order system

Abstract

Value Stream Mapping of the Singapore operations of a multi-national food products packaging company was carried out with the objective of streamlining production in accordance with the World Class Manufacturing philosophy. An opportunity for reduction in WIP and lead time was identified. Simulation models were used, on the make- to-order, serial production system to test three potential solutions to the problem. The models used showed great promise for reduction in WIP and the lead time for both the priority and ordinary products. The role of design as a sorting criterion on the printer was also investigated by a fundamental integer programming model using the Travelling Salesman approach. Results confirming the significance of design in the printer setup process were obtained in the trial run.