Research on optimization and simulation of sand casting production line based on VSM
International Journal of Lean Six Sigma
ISSN: 2040-4166
Article publication date: 16 February 2022
Issue publication date: 18 October 2022
Abstract
Purpose
This paper aims to provide feasible countermeasures for the application of lean manufacturing in automatic sand casting workshops to optimize production line balance.
Design/methodology/approach
A production line balance optimization model for sand casting workshops is proposed. The value stream mapping (VSM) approach is applied to diagnose the problems in the production process. An optimization scheme is established based on eliminate, combine, rearrange, simplify and increase theory and Kanban management method. Further, simulation is done to compare current VSM and future VSM.
Findings
After implementing the proposed model, findings indicated that the idle time of equipment was effectively reduced, the line of balance of the production line was increased by 44.7%, the production lead time was shortened by 60.3% and the production capacity was increased by 50.0%.
Research limitations/implications
Application of the optimization model in this study is limited to sand casting workshops that have realized automatic or semi-automatic production.
Originality/value
This paper provides an optimization model for the implementation of lean manufacturing in sand casting workshops and provides a reference case that reflects the actual application of lean manufacturing tools in a real situation.
Keywords
Acknowledgements
Funding: Guangzhou Innovation Leadership Team Project (201909010006). Science and technology plan project in Inner Mongolia autonomous region (2019GG238). National Natural Science Foundation of China (51875251). Special Funds for Fundamental Scientific Research Funds of Central Universities (21620360). Guangdong Higher Education Educational Teaching Research and Reform Project (2020059). Guangdong Basic and Applied Fundamental Research Fund Joint Fund Youth Fund Project (2019A1515110399). Panyu District Innovation and Entrepreneurship Leading Team Project (2018-R01-4). Jinan University Graduate Education and Teaching Achievement Cultivation Project (2021YPY010). Jinan University off-campus students Practical Teaching Base Construction Project (55691207). Guangdong Provincial Degree and Graduate Education Reform Research Funding Project (2019JGXM15). Major project of Science and Technology Plan of Hohhot (2020-Gao-Zhong-4). Guangzhou Science and Technology Program key projects (202002030321). Guangdong Graduate Education Innovation Program (82620516).
Citation
Chao, B., Zhang, C., Zhang, Y., Guo, H., Ren, Y. and Zhang, H. (2022), "Research on optimization and simulation of sand casting production line based on VSM", International Journal of Lean Six Sigma, Vol. 13 No. 6, pp. 1185-1199. https://doi.org/10.1108/IJLSS-10-2021-0183
Publisher
:Emerald Publishing Limited
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