VALUE STREAM MAPPING FOR OPERATIONS AND SUPPLY CHAIN COORDINATION IN INDONESIAN AUTOMOTIVE MANUFACTURING
Published:
2025-12-30Downloads
Abstract
Operations and supply chain decisions require a consistent view of processing capacity, inventory, and replenishment. This study develops an analytical planning case for an automotive component supplier in West Java, Indonesia. Baseline and proposed value stream maps (VSM) are evaluated using takt time, inventory coverage, ideal capacity, and demand sensitivity. At 360 units per day and 25,920 available seconds, takt time is 72.00 seconds. The proposed design reduces inventory from 3,600 to 1,080 units and processing content from 282 to 230 seconds. The coverage-based lead-time indicator decreases from 10 to 3 working days. Ideal line capacity increases from 316.10 to 446.90 units per day. At demand of 396 units and 90% effective operating time, utilization reaches 98.46%. The analysis connects inventory targets with capacity restrictions and replenishment rules.
Keywords:
Inventory control Lean manufacturing Operations Supply chain Value stream mapping (VSM).References
Badan Pusat Statistik. (2024). Statistik Indonesia 2024 [Statistical yearbook of Indonesia 2024]. https://www.bps.go.id/id/publication/2024/02/28/c1bacde03256343b2bf769b0/statistik-indonesia-2024.html
Batwara, A., Sharma, V., Makkar, M., & Giallanza, A. (2023). Towards smart sustainable development through value stream mapping: A systematic literature review. Heliyon, 9(5), Article e15852. https://doi.org/10.1016/j.heliyon.2023.e15852
Buer, S.-V., Semini, M., Strandhagen, J. O., & Sgarbossa, F. (2021). The complementary effect of lean manufacturing and digitalisation on operational performance. International Journal of Production Research, 59(7), 1976–1992. https://doi.org/10.1080/00207543.2020.1790684
Busert, T., & Fay, A. (2021). Information quality focused value stream mapping for the coordination and control of production processes. International Journal of Production Research, 59(15), 4559–4578. https://doi.org/10.1080/00207543.2020.1766720
Ferreira, W. de P., Armellini, F., Santa-Eulalia, L. A. de, & Thomasset-Laperrière, V. (2022). Extending the lean value stream mapping to the context of Industry 4.0: An agent-based technology approach. Journal of Manufacturing Systems, 63, 1–14. https://doi.org/10.1016/j.jmsy.2022.02.002
Hamsal, M., Dwidienawati, D., Ichsan, M., Syamil, A., & Trigunarsyah, B. (2022). Multi-perspective approach to building team resilience in project management: A case study in Indonesia. Sustainability, 14(20), Article 13137. https://doi.org/10.3390/su142013137
Horsthofer-Rauch, J., Guesken, S. R., Weich, J., Rauch, A., Bittner, M., Schulz, J., & Zaeh, M. F. (2024). Sustainability-integrated value stream mapping with process mining. Production & Manufacturing Research, 12(1), Article 2334294. https://doi.org/10.1080/21693277.2024.2334294
Ivanov, D. (2022). Lean resilience: AURA (Active Usage of Resilience Assets) framework for post-COVID-19 supply chain management. The International Journal of Logistics Management, 33(4), 1196–1217. https://doi.org/10.1108/IJLM-11-2020-0448
Ivanov, D., & Dolgui, A. (2020). Viability of intertwined supply networks: Extending the supply chain resilience angles towards survivability. A position paper motivated by COVID-19 outbreak. International Journal of Production Research, 58(10), 2904–2915. https://doi.org/10.1080/00207543.2020.1750727
Jamil, N., Gholami, H., Mat Saman, M. Z., Streimikiene, D., Sharif, S., & Zakuan, N. (2020). DMAIC-based approach to sustainable value stream mapping: Towards a sustainable manufacturing system. Economic Research-Ekonomska Istraživanja, 33(1), 331–360. https://doi.org/10.1080/1331677X.2020.1715236
Kim, K. I., Syamil, A., & Bhatt, B. J. (2007). A resource-based theory of supplier strategy. International Journal of Logistics Systems and Management, 3(1), 20–33. https://doi.org/10.1504/IJLSM.2007.012073
Klimecka-Tatar, D., & Obrecht, M. (2024). Development and improvement of a production company (and their product) based on the value stream mapping of business processes. Management Systems in Production Engineering, 32(2), 185–191. https://doi.org/10.2478/mspe-2024-0018
Nunes, F. de L., Chika, L. P., & Santos, C. (2024). MIF: A mapping approach based on the combination of VSM 4.0 and Shingo production engine applied in a case study of Brazilian logistics distribution centre. International Journal of Process Management and Benchmarking, 18(2), 183–215. https://doi.org/10.1504/IJPMB.2024.141536
Pradeep, A., & Balaji, K. (2022). Reduction of lead time in an automobile rubber components manufacturing process through value stream mapping. Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 236(6), 2470–2479. https://doi.org/10.1177/09544089221094094
Razali, G., Syamil, A., Hurit, R. U., Asman, A., Lestariningsih, Radjawane, L. E., Bagenda, C., Falasifah, N., Amane, A. P. O., Tingga, C. P., Saloom, G., Sumarni, S., Gultom, N. B., Fadhilatunisa, D., Fakhri, M. M., & Rosidah. (2023). Metodologi penelitian kuantitatif, kualitatif, dan kombinasi. Media Sains Indonesia.
Rosin, F., Forget, P., Lamouri, S., & Pellerin, R. (2020). Impacts of Industry 4.0 technologies on lean principles. International Journal of Production Research, 58(6), 1644–1661. https://doi.org/10.1080/00207543.2019.1672902
Schumacher, S., Hall, R., Bildstein, A., & Bauernhansl, T. (2023). Lean production systems 4.0: Systematic literature review and field study on the digital transformation of lean methods and tools. International Journal of Production Research, 61(24), 8751–8773. https://doi.org/10.1080/00207543.2022.2159562
Tortorella, G. L., Pradhan, N., Macias de Anda, E., Trevino Martinez, S., Sawhney, R., & Kumar, M. (2020). Designing lean value streams in the fourth industrial revolution era: Proposition of technology-integrated guidelines. International Journal of Production Research, 58(16), 5020–5033. https://doi.org/10.1080/00207543.2020.1743893
License
Copyright (c) 2025 Ahmad Syamil
This work is licensed under a Creative Commons Attribution 4.0 International License.
