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Reducing Turn Around Time in Laboratory Using Value Stream Mapping
Reducing Turn Around Time in Laboratory Using Value Stream Mapping
Reducing Turn Around Time in Laboratory Using Value Stream Mapping
Abstract
The effectiveness and efficiency of production II. BACKGROUND
process flow can be achieved by reducing the waste
identified in the process flow. Value Stream Mapping A. Lean
(VSM) is a basic method in lean manufacturing Lean concepts are mostly evolved from
systems to identify and eliminate waste. The purpose Japanese industries especially from Toyota. Lean
of this research is to identify with Value Stream Manufacturing is considered to be a waste reduction
Mapping (VSM) method on activities that provide technique as suggested by many authors, but in
value and eliminate other activities that do not practice lean manufacturing maximize the value of the
provide value (waste) in one of the chemical testing product through minimization of waste. Lean
laboratory. Research was conducted in several principles defines the value of the product/service as
important stages, namely the selection of product perceived by the customer and then making the flow
types to be observed, the making of the VSM of the in-line with the customer pull and striving for
current condition to the selected product, the analysis perfection through continuous improvement to
of VSM improvement of the current conditions, and eliminate waste by sorting out Value Added
then making the recommendation improvement. In activity(VA) and Non- Value Added activity(NVA).
this article we can describe current state of the The sources for the NVA activity wastes are
process and we can reduce Turn Around Time by give Transportation, Inventory, Motion Waiting,
suggestion to the laboratory. Overproduction, Over processing and Defects. The
NVA activity waste is vital hurdle for VA activity.
Elimination of these wastes is achieved through the
Keywords: Lean, VSM, Value Stream Mapping,
successful implementation of lean elements. [3]
Laboratory.
Lean arise from the Toyota Production System.
I. INTRODUCTION The variants of Lean Manufacturing, such as TQM,
were originally founded in the Japanese automotive
Views of third party testing laboratory business industry, but their evolution was mostly carried out in
nowadays already change, at the beginning only focus the West. Lean is a production practice that considers
on result quality, including accuracy and precision, the expenditure of resources for any goal other than
now also start to give customer more faster analysis the creation of value for the end customer to be
time. This happen because customer requirement wasteful and thus a target for elimination; basically,
increase more fasten delivery time to make their more value with less work. Lean is a generic process
production system more efficient. And third party management philosophy derived originally from the
testing laboratory need to speed up the testing process Toyota Production System (TPS). The term „Lean‟
to support the industry. In industry, most big and was probably coined by Womack et al. in their book
successful company use Lean Management to „The Machine that Changed the World‟. Some
eliminate waste, cost saving and also reduce delivery authors‟ state that a definition of Lean includes both
time [1]. the people and the process components on the one
hand and internal (related to the firm) and external
Value Stream Mapping (VSM) are one of the (related to supplier and customer) components on the
tools for Lean Management. Value Stream Mapping other hand. So, Lean is the production of goods using
(VSM) is an effective tool of Lean Manufacturing to less of everything. In using Lean with your company,
reduce the wastage in any process by segregating the goals would be to use less waste, less human effort,
Value Added (VA) and Non-Value Added (NVA) less manufacturing space, less investment in tools and
Activities. Lean techniques are focus on reducing lead less engineering to develop a new product. Lean is
time and eliminating wastes in all kind of forms [2]. renowned for its focus on the reduction of waste,
This paper will focusing apply VSM from industry which in turn improves overall customer value. [4]
into laboratory for increasing delivery time to
customer. Contemporarily, the implementation of lean
manufacturing is methodically elaborated under the
assumptions that waste elimination, which can be
divided into nine categories (overproduction, motion,
waiting, transportation, inventory, defects, may used as future state visualization tools as we seen
over-processing, not-utilized talent and unsafe or at Figure 1. [9]
ergonomic working conditions), can be guaranteed by
the application of a few organization techniques in a If we successfully mapping our business process
defined sequence. Among them the following can be trough VSM, we can see which part is have lot of
distinguished. [5] waste time, and we can focus doing improvement on
that part. By the customer point of view, they don‟t
Workplace organization – 5S – sort, set in order, needed waste that we create in our business
shine, standardize and sustain process.Toyota identified 7 waste that we will
identified in our business system are[10] :
Visualization of work and its results
1. Overproduction: Producing items for which there is
Standardization no order.
Complex maintenance – TPM (Total Productive 2. Waiting Time: Employee standing about.
Maintenance)
3. Unnecessary Transport: Moving materials
Fast refitting – SMED (Single Minute Exchange optionally or long distances.
of Dies)
4. Over-processing: Using more steps to produce a
Implementing quality in processes and product than required.
continuous improvement.
5. Excess Inventory: Holding unnecessary inventory
B. Value Stream Mapping (VSM) between process steps.
Value stream mapping is a
method of lean manufacturing which uses symbols, 6. Unnecessary Movement: Any waste motion by
metrics and arrows to show and improve the flow of man or machine.
inventory and information required to produce a
product or service which is delivered to a consumer. A 7. Defect: Making defective product
value stream map is a visual representation which
enables one to determine where the waste occurs. [6] VSM is a tool to increase a firm‟s efficiency, and
Value Stream Mapping is a simple, yet very effective, is typically used to identify the transformation of
method to gain a holistic overview of the conditions of information flow of raw material into the finished
the value streams within an organization. Based on the product or service of a value, customers are willing to
analysis of the current-condition, flow-oriented target pay for. Benefits of VSM are that it enables
value streams (target-conditions) are planned and visualization of the entire process, identifies flow
implemented. [7] decision, links between operations and provides an
VSM includes a set of all activates (value added as-is and to-be state map. VSM tools and found that
as well as non-value added) that are essential to bring managers reported that VSM was beneficial in
a product through the main flows, starting with raw eliminating waste, focusing on key issues, and would
material, and ending with the customer. The main goal continue to be important in the coming years. Applied
of VSM is to find different types of wastes and trying VSM to complex production systems and conducted a
to eliminate them. The first step is to select a specific case study to assess the validity of their proposed
product or product family as the target for methodology and found that it is beneficial in
improvement. The second step is that to develop a handling complexity. VSM not only highlights
current state map that is mainly a snapshot capturing process inefficiencies, but also serves as an excellent
how processes are currently being done. The third step form of guidance regarding improvement areas for
is to draw the future state map that is a picture of how organizations, hence providing efficient learning
the production process should be done after the wastes opportunities. There is an established practice to
and inefficiencies have been removed. The future perform VSM of different processes to identify
state map is created based on answering a collection bottle-necks and points of improvements. Using VSM
of questions on topics relevant to efficiency as well as is recognized as a tool to improve the efficiency and
implementing technical issues related to the effectiveness of manufacturing and logistical
application of lean techniques. Finally, the suggested processes. However, reviewing more flexible and
map is applied as a basis for making essential changes dynamic processes holds some novelty within the
to the system.. [8] field of advanced manufacturing. [11]
VSM itself consist of two groups : Value Added III. CASE STUDY
(VA) Work and Non-Value Added (Work). and VSM
present chart-like mapping process from start untill Chemical Textile Laboratory is selected as a case
end of the product ready deliver to customer. Or it study in this article. This company is one of a leading
laboratory in the world. A multinational testing
laboratory and we work in two shift in 8 hour per waste is generate form the inventory. As we can see
shift, total worker around 150 people. And one of the that the most of waste is in inventory due to still using
major test is azo dyes test. After simulation, we of batch working procedure in the laboratory and that
calculate in current state lead time in azo dye test are is unavoidable. Due to condition of laboratory isn‟t
7.4 hours. And we also identified waste in the current same with the manufacturing that we can apply flow
state of working condition are motion, inventory, through system using push or pull system, batch
waiting and transportation. system still in use in most of the laboratory. And form
the table 1 we can see inventory is the most factor
IV. RESULT AND DISCUSSION generate waste in the azo dye test. Author with the
team do brainstorming, analyse, and conclude that
A. Current State of VSM happen because some condition like :
Value Stream Mapping are a 1. Most of the analyst in this laboratory is not doing
planning and evaluation tool for improving the overall one test only, they multi-tasking to do another
customer experience, is an attractive alternative in the test.
arsenal of lean-manufacturing tools. VSM addresses 2. No dedicated equipment for specific test, most of
the flow of materials and information that are needed the equipment are sharing with another test.
to bringa product or service to a customer. It has many 3. Most of chemical reagent is made freshly, analyst
benefits including [12]: need to calculate of no of test and made the fresh
Quick and easy to learn reagent based on the calculation.
Identifies bottlenecks From Table 1, we can analyze the bottleneck of
Identifies waste azo dyes testing in chlorobenzene extraction. Author
Inexpensive with the team analyze that because we use one soxhlet
Focuses on no and low-cost improvements extractor for one hot plate, that cause long waiting
Uses a common language time in the testing process. It happen because process
As shown in figure 2 below, the current state of time in this step is around 30 minutes, so another
azo dyes test work and we can see also waste that sample in the batch need to queue in this process.
generate in every step. In Table 1 we can see waste
that generate in every step of testing, but the most
REFERENCES
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a Tool to Develop Green Manufacturing.
http://www.sciencedirect.com.
[3] Sundar, R., Balaji, A.N., Kumar, R.M.S. (2014). A Review on
Lean Manufacturing Implementation
Techniques.http://www.sciencedirect.com.
[4] Anvari, A., Ismail, Y., Hojjati, S.M.H. (2011).A Study on
Total Quality Management and Lean Manufacturing:
Through Lean Thinking Approach.
https://www.researchgate.net.