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<p>Lean Manufacturing (LM), pioneered in Japan, is a business strategy focused on identifying and eliminating waste to boost competitiveness through enhanced productivity and quality. Existing literature on electronics manufacturing often emphasizes broad flow improvements but lacks process-specific analysis and dynamic validation. To address this gap, our research captures detailed production metrics over ten days on an LED TV line and validates lean-driven future state improvements using Arena discrete-event simulation (DES) that ensures data-driven, context-rich decision-making and bridges the gap between static mapping and real-world variability. The production process was segmented into six sections PCBA (Printed Circuit Board Assembly), Speaker, AC Cord, Remote, Display, and Final Assembly with a combined cycle time of 6.06&#xa0;h. Current-state mapping revealed extraordinarily low efficiencies and high NVA (Non-Value-Added Time), particularly in PCBA and final Assembly. Lean VSM (Value Stream Mapping) workshops were conducted to construct a future-state map, guided by takt time, cross-functional collaboration, and bottleneck analysis. The proposed framework was evaluated using a real-world case study within a leading Bangladeshi electronics manufacturer and validated through multiple simulation scenarios conducted in Rockwell Arena. Its effectiveness was measured via key performance indicators including lead time reduction, non-value-added time, cycle-time efficiency, and overall throughput. Results demonstrate a significant (~ 9.6%) decrease in lead time and NVA, a 3.8% reduction in cycle time, and an impressive 6.5% boost in overall efficiency. Simulation replications confirmed consistent performance gains, with zero adverse impacts on quality or production stability.</p>

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Lean Optimization of LED-TV Manufacturing: Integrating Value Stream Mapping with Discrete-Event Simulation

  • 期刊论文

  • 发表日期：

    2025年12月6日

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  • Tamanna Kamal,
  • S. M. Atikur Rahman,
  • Arif Mahmud

摘要

Lean Manufacturing (LM), pioneered in Japan, is a business strategy focused on identifying and eliminating waste to boost competitiveness through enhanced productivity and quality. Existing literature on electronics manufacturing often emphasizes broad flow improvements but lacks process-specific analysis and dynamic validation. To address this gap, our research captures detailed production metrics over ten days on an LED TV line and validates lean-driven future state improvements using Arena discrete-event simulation (DES) that ensures data-driven, context-rich decision-making and bridges the gap between static mapping and real-world variability. The production process was segmented into six sections PCBA (Printed Circuit Board Assembly), Speaker, AC Cord, Remote, Display, and Final Assembly with a combined cycle time of 6.06 h. Current-state mapping revealed extraordinarily low efficiencies and high NVA (Non-Value-Added Time), particularly in PCBA and final Assembly. Lean VSM (Value Stream Mapping) workshops were conducted to construct a future-state map, guided by takt time, cross-functional collaboration, and bottleneck analysis. The proposed framework was evaluated using a real-world case study within a leading Bangladeshi electronics manufacturer and validated through multiple simulation scenarios conducted in Rockwell Arena. Its effectiveness was measured via key performance indicators including lead time reduction, non-value-added time, cycle-time efficiency, and overall throughput. Results demonstrate a significant (~ 9.6%) decrease in lead time and NVA, a 3.8% reduction in cycle time, and an impressive 6.5% boost in overall efficiency. Simulation replications confirmed consistent performance gains, with zero adverse impacts on quality or production stability.