Improving Process Efficiency in High Variant Industry Using Integrated Method of Value Stream Mapping and Overall Equipment Effectiveness

Production efficiency remains a critical challenge where high product variability and equipment-intensive processes often lead to substantial downtime and inefficiencies. While VSM and OEE are widely used for performance improvement, they are commonly applied separately, limiting comprehensive evaluation of process waste and equipment losses. This study proposes an integrated VSM OEE framework to improve process efficiency in a cosmetic packaging production line, to identify value-added and non-value-added activities, and quantified equipment losses through availability, performance, and quality indicators. Improvement strategies were developed using the ECRS method and evaluated through a Future State VSM. Implementation of the proposed improvements reduces downtime by 85.5%, leading to PCE improvements to 76.88%, respectively. The findings demonstrate that integrating VSM and OEE provides a more comprehensive and analytically robust approach to diagnosing and improving production efficiency, contributing to the advancement of lean manufacturing practices.