The aim of the research is to analyze the performance and efficiency of the production processes of dish-washing machines in order to increase the production capacity. Initially, the production processes of a selected dish-washer model in the production line are observed, and the duration of all process steps are measured via time study. Then the process parameters, i.e. cycle time, changeover, inventories as well as the information flows are analyzed with the Current State Value Stream Map. Improvement opportunities based on findings are discussed with the company managers. Afterwards, a simulation model of the system is developed via Arena Simulation Software. Various improvement scenarios are simulated, before-after situations are compared with the simulation model, and the one giving the best output is displayed in the Future State VSM.

1. Ali TURAN
Berkay MANDAL
Ekin YILDIRIM
Eylül Ceren ALTIN
Yüksel YALÇIN
Advisor: Assist. Prof. Dr. Zeynep Doğruöz Gergin
39th Operations Research / Industrial Engineering National Congress
June 12-14, 2019
PERFORMANCE AND EFFICIENCY ANALYSIS WITH VALUE STREAM
MAPPING FOR INCREASING PRODUCTION CAPACITY

2. CONTENT
Company Information
Motivation & Objectives
Methodology
Implementation & Results
Conclusion & Recommendations

3. COMPANY INFORMATION
• Öztiryakiler was established in 1958
as one of the first manufacturing
companies of Turkey in
kitchen equipment sector.
• 5 continents, over 100 countries
• 10 group companies with 1300
employees
• 149.500 m² in 5 different production
plants

4. MOTIVATION OF THE
STUDY
• Improvement needs on the current
efficiency and capacity of
dishwashing machine’s production
line.
• Non-value adding processes in the
system.
• Requirements for identifying the
wastes in production line, in order to
eliminate them.

5. OBJECTIVES
❑ Analyzing the performance and
efficiency of the production
processes of dishwashers.
❑ Increasing the production capacity.

6. METHODOLOGY
Observing The Process Steps
Time Studies (Data Collection)
Developing Current State VSM
Analyzing Current Effective Capacity
Discussing İmprovement Scenarios With A Simulation Model
Developing Future State VSM Based On İmprovement Scenarios

7. IMPLEMENTATION
Assembly 1
19 Work
Elements
Assembly 2
15 Work
Elements
Assembly 3
Operation 1
6 Work
Elements
Assembly 3
Operation 2
9 Work
Elements
Electrical
Components
Assembly
21 Work
Elements
Packaging
16 Work
Elements
TIME STUDY
Figure 1. Production flow

8. IMPLEMENTATION
TIME STUDY
Figure 2. Current Processes Durations
Table 1. Process Time Study Results

9. CURRENT STATE VSM
NVA ∑ 28040 sec 0,83 NVA
VA ∑ 5555 sec 0,17 VA
Lead Time 33595 sec
896
324
903 1360
1315440 8250 70 163 4480 4084 116
1021972403
1224860
Assembly 1 Electrical Components
Assembly
Assembly 3Assembly 2 Packaging
I
Scheduler
SupplierSupplier Customer
C/T = 903sec
C/O = 324 sec
1 Shift
C/T = 1360 sec
C/O = 131 sec
1 Shift
C/T = 896 sec
C/O = 122 sec
1 Shift
C/T = 1375 sec
C/O = 233 sec
1 Shift
C/T = 1021 sec
C/O = 116 sec
1 Shift
Operation 1 for
Assembly 3
C/T = 403 sec
C/O = 70 sec
1 Shift
Operation 2 for
Assembly 3
C/T = 972 sec
C/O = 163 sec
1 Shift
PURCHASING SALES & MARKETING
1 2 2 2 1
I I I
I
4 units 6 units 4 units5 units
5 unitsof
dishwashing
machine's
upperpart
Daily
Weekly WeeklyWeekly
WeeklyWeekly
Daily
I
WeeklyMonthly
Weekly
Monthly
Kaizen 1Kaizen 3Kaizen 2
Figure 4. Current State VSM

10. KAIZEN PROPOSALS
Assembly 3
C/T = 1375 sec
C/O = 233 sec
1 Shift
Operation 1 for
Assembly 3
C/T = 403 sec
C/O = 70 sec
1 Shift
Operation 2 for
Assembly 3
C/T = 972 sec
C/O = 163 sec
1 Shift
2
I I
I
units 5 units
5 unitsof
dishwashing
machine's
upperpart
Kaizen 1
Assembly 1
IC/T = 903sec
C/O = 324 sec
1 Shift
1
4 units
Weekly
Kaizen 2
Assembly 2
I C/T = 1360 sec
C/O = 131 sec
1 Shift
2
I
4 units 6 units
Kaizen 3

11. SIMULATION MODELING_Current values
Total Work Hours in a Day 24 hours 24x60x60 86400 sec
Total Shift Hours in a Day 8 hours 8x60x60 28800 sec
Total Cycle Time + Total
Changeover Time
6481
Current VSM Bottleneck 1608
Table 2. Production Line Durations (Current VSM)
DESIGN CAPACITY
EFFECTIVE CAPACITY

12. ARENA SIMULATION MODELLING

13. ESTIMATIONS OF NEW PROCESS DURATIONS
Process Name Set Up Process Time
Total Process
Time
Rezistans İşaretleme ve Çakma 30.12 93.24 123.36
Process Name Set Up Process Time
Total Process
Time
Rezistans İşaretleme ve Çakma 24.12 93.24 117.36
Table 3. Current Time Study Example
Table 4. Future Time Study Example
Table 5. Production Line Durations (Future VSM)
Total Work Hours in a Day 24 hours 24x60x60 86400 sec
Total Shift Hours in a Day 8 hours 8x60x60 28800 sec
Total Cycle Time + Total
Changeover Time
5944
Current VSM Bottleneck 1343
CURRENT STATE
FUTURE STATE

14. SIMULATION MODELING_Future values
DESIGN CAPACITY
EFFECTIVE CAPACITY

15. FUTURE STATE VSM
NVA ∑ 9573 sec 0,65
VA ∑ 5164 sec 0,35
Lead Time 14737 sec
116
1021
122
896
1132 1792 10214848
903
248
1212
163
1132
131
Assembly 1 Electrical Components
Assembly
Assembly 3Assembly 2 Packaging
I
Scheduler
SupplierSupplier
Customer
C/T = 903sec
C/O = 248sec
1 Shift
C/T = 1212 sec
C/O = 131 sec
1 Shift
C/T = 896 sec
C/O = 122 sec
1 Shift
C/T = 1132 sec
C/O = 163 sec
1 Shift
C/T = 1021 sec
C/O = 116 sec
1 Shift
PURCHASING SALES & MARKETING
1 2 2 2 1
4 units
Daily
Weekly WeeklyWeekly
WeeklyWeekly
Daily
I
WeeklyMonthly
Weekly
Monthly
I
1 units
I
2 units
I
1 units
Figure 5. Future State VSM

16. COMPARATIVE RESULTS
Effective
Capacity
Design
Capacity
Current State
VSM
15 51
Future State
VSM
18 61
Figure 3. Current State Process Durations Figure 4. Future State Process Durations

17. CONCLUSION & RECOMMENDATIONS
Current CSM Future VSM Change % 
Change over time 926 sec 780 sec 15.80 % 
Total Non value adding times 28,040 sec 9573 sec 65.85 % 
Cycle time (VA) 5555 sec 5164 sec 7.04 % 
Lead time 0.39 days 0.17 days 56.41 % 
VA / Lead time 16.54 % 35.04 % 112 % 
Effective capacity 15 units 18 units 20.00 % 
Design capacity 51 units 61 units 19.61 % 
Table 6. Comparative Results and Improvements

18. THANK YOU FOR YOUR
ATTENTION!