Production efficiency improvement in batch production system using value stream mapping and simulation: a case study of the roasted and ground coffee industry

This article involves the use of value stream mapping (VSM) and simulation to improve the efficiency of the batch production system commonly found in small and medium enterprises. VSM is a tool for portraying the system to identify areas for improvement. The simulation model imitates a real production system so that improvement alternatives can be evaluated without disrupting actual production. The simulation can also optimise the levels of resources required for the bottleneck operations. The production process at a roasted and ground coffee plant that had serious capacity shortage problem is used as a case study. Three improvement alternatives are evaluated: (1) increasing the workforce at the bottleneck operations; (2) using a new workforce management plan formulated from analysing the VSM and simulation and (3) investing in a machine to replace the bottleneck manual operations. Analysis results show the capability of these tools to formulate effective solutions for the case study system.