Production system state analysis and improvement using VSM, simulation, and fuzzy logic

Purpose The paper aims to provide a door-to-door holistic perspective on the state of a production system based on several metrics and their relationships, to utilize a combination of tools and techniques and to develop a unique model for production system assessment. The study addresses the limitations of narrow approaches by proposing a new metric as a single indicator of the production system’s overall state. Design/methodology/approach The research methodology adopted is design science research. It proposes a framework that combines value stream mapping, simulation and fuzzy logic to study the impact of different lean interventions on the overall state. An offsite construction facility was used as a case study. Data were gathered using methods such as ethnography, interviews, time and motion studies, shopfloor observations, video surveillance and database exploration. Findings The paper highlights how some interventions can have local improvements but lead to negative impacts on the overall system state. It emphasizes the importance of having a holistic approach to analyze and improve the true state of a production system. Research limitations/implications The study excludes impacts of the supply chain and assumes the system to be confined within the shopfloor. Researchers are encouraged to include those variables in future studies. Practical implications The study presents a practical framework and tool that can be tailored to any production system and be used to improve its performance. Originality/value This paper proposes a unique framework and a new metric for system state assessment and improvement.