Creating lean value streams through proactive variability management

Complex product and production systems often result in high variability in the production flow, prohibiting the sustainable implementation of lean practices. In this paper the authors introduce a PDCA cycle to analyse and reduce variability in value streams. The value stream is divided into zones, which are then qualified as stable or unstable. Lean practices can be applied in stable zones, unstable zones remain expert-driven. Measures are introduced to reduce variability in unstable zones with the ultimate target, to turn them into stable zones, extending sustainable lean activities in the value stream, step by step. An IT system is developed to acquire, process and visualise the vast amount of data to provide structured information for experts and management for the reduction of variability in production.

Automated summary

This paper introduces a PDCA cycle to analyze and reduce variability in value streams. It divides the value stream into stable and unstable zones, and applies measures to reduce variability in the unstable zones, with the goal of gradually turning them into stable zones and extending the sustainable implementation of lean practices. An IT system is developed to acquire, process, and visualize the data, providing structured information for experts and management to reduce production variability.