RFID- Enabled Dynamic Value Stream Mapping

Muawia Ramadan, ZelongWang, Bernd Noche

Transport Systems and Logistics Engineering Institute
Mechanical Engineering Department
Duisburg-Essen University
Duisburg 47058, Germany

Abstract-Value Stream Mapping (VSM) is one of the most manufacturing system, from door to door. But due to its
powerful lean manufacturing tools used for quick analyses of weakness in covering some issues in the manufacturing
products and information flow through a manufacturing system facilities, beside that it displays the information for specific
from door to door. This versatile, powerful method is used to period of time from total production time which serves just as
visualize product flows as snapshot; it just describes the snapshot - static - description of the production behavior.
production behavior within specific period from the total
Therefor this work is a trying to improve the VSM abilities by
production time; which some time cause a misleading during lean
utilizing RFID capabilities in VSM; it becomes called dynamic
tools implementation. In this paper a new real-time data
value stream mapping (DVSM). RFID will be integrated in
collection called Radio Frequency Identification (RFID) system
VSM as real-data collection tool to fill the gap between
will be integrated in VSM to collect the objects information
physical flow of products or objects and the corresponding
through a manufacturing system in the production floor. The
information flow. The DVSM will be used as starting point for
new integrated RFID-VSM system called Dynamic Value Stream
implementing lean manufacturing tools like Just-In-Time (TIT)
Mapping (DVSM) Provides a real-time data for VSM to be able
to interact with the processes, people, material, and any other , Kanban system , Total Productive Maintenance (TPM) ,
constraint relevant to the production situation. As time quality issues while after lean implementation its used as
progresses and the operation are "producing", the workers and continuous real-time production monitoring tool to ensure the
managers will have the ability to interact live with the animated consistency of lean tools implementation and for continuous
flow. Queues build up, inventory deplete, people move, etc... measuring of production performance for further improvement
Based on the real situation the managers can take the right opportunity.
decision at the right time where the workers will make changes
to processing capacity, labor requirements, flow, and cell layout,
II. TRADITIONAL VALUE STREAM MAPPING
to optimize and design or develop the future state.
Value stream mapping is well known as material and
Keywords- Value stream mapping, Radio frequency information flow mapping. VSM can serves as a starting point
identification system, Dynamic Value stream mapping, Just-in­ for management, engineers to recognize and identify waste and
Time, Kanban. the corresponding causes. VSM has been discussed in detailed
about its application in manufacturing (i.e. physical
I. INTRODUCTION transformation) in Rother and shook book "learning to see" [6].
Despite VSM benefits but it still has some weaknesses as it is
With the increased customer demand , market
normally used [8].
fluctuations , and the need for fast information flow within
most manufacturing industries today it has become Rother and shook [6] stated the way of taking the
increasingly important to continuously analyze and improve information by walking along the actual pathways of material
the manufacturing system and the corresponding planning and information; this means , a general information will be
system. The most widely known approach for improvement collected rather than the real information; the collected
work performance is lean manufacturing. information in this simple way is misleading information for
the managers who want to improve the production system or
The lean concept was defmed by [1] and [2]. Within lean
take decisions . From their side this method of collecting the
there are tools and methods that are used for different purposes
aggregated data is usually more convenient than timing every
in the organizations. Because of many potential benefits of
work piece going through the production line. Therefore,
lean manufacturing, much attention has been focused on
obtaining the time averages of a VSM requires less effort
advancing its tools, techniques, and implementation strategies
than collecting detailed data from the individual work
in recent years. Further discussions can be found in Bozzone
piece. But the averages are capable of representing just the
[3], Edwards [4], Feld [5], Rother and Shook [6], and Storch
general conditions of the value stream. However, an average
and Lim [7].
number cannot display the variability of the actual conditions
The first step toward lean is VSM; it's a traditional lean or the enough deeply description of the actual situation. The
tool used for quick analyses of product flow through a lost information may contain clues of the actual leanness level

978-1-4673-2401-4112/$3l.00 ©2012 IEEE 117

Authorized licensed use limited to: UNIVERSITY PUTRA MALAYSIA. Downloaded on March 18,2021 at 06:02:41 UTC from IEEE Xplore. Restrictions apply.
and potential improvements. Therefore utilizing an automatic
data collection technology (Auto-ID) can serves as accurate
and fast automatic data collection for the interacted objects in
the production system,which gives the management a detailed
description about actual condition of the production line.
where RFID tag is used to enable accurate customization of
customer orders, a read/write smart tag is programmed
according to the customer order specifications, and then its
attached to the car body and travels with it during the
production process, this tracking ensure that the car is
manufactured with the correct production process at each

III. FRID AND ITS USES IN PRODUCTION AND SUPPLY workstation relating to the customer specifications
[IO].However, as the technical prerequisites of RFID
CHAIN MANAGEMENT
installation in the supply chain have been addressed by the
EPC global. Its beginnings in an academic research center
A. RFID Essentials
based at the MIT called the Auto-ID Center [11].
Although the scope of this paper is not to give a
detailed insight into the RFID technology itself, but it is
mandatory to have a basic understanding of the underlying IV. INTEGRATION RFID TECHNOLOGY IN VALUE STREAM

technology . RFID is an emerging technology intended to MAPPING

complement or replace traditional barcode technology to The basic idea of utilizing lean manufacturing concepts in
identify, track, and trace items automatically. RFID is any enterprise is to eliminate the waste in all activities in all
claimed to add intelligence to and to minimize human phases especially in production phases to improve the
intervention in the item identification process by using productivity, reactivity of production to different external or
electronic tags[9] .The basic components of RFID system is internal fluctuation, quality and total performance of the
consist from three components. 1- Transponders (Tags) that enterprise, Therefore, the implementation of lean tools and
allow items to be identified. 2- Antennas and Readers/writers principles start by drawing the VSM which is considered the
that allow tags to be interrogated and to respond. 3- most powerful lean tool and the best starting point to
Software that controls the RFID equipment and manages the implement other lean concepts due to its ability to visualize the
data and interfaces with enterprise applications. Note that the current situation of the production and identifies not just the
exact configuration of a particular deployment depends on wastes but also the source of the wastes in value stream. It has
the vendor, system integrator, and the application. the ability also to tie together lean concepts,techniques,people
and methods during the transformation from current to future
In a typical manufacturing scenario, for example, readers
VSM.
will be picking up a continuous stream of tag data,which might
contain errors such as duplicate reads and phantom-reads. The
job of the software is to filter and manage this data and A. Dynamic Value Stream Mapping as Continuous Real -

forward only clean data in order to avoid overwhelming Time Production Monitoring Tool

enterprise applications [9]. Extensive studies were performed on various subjects

related to VSM; but most of them didn't focus directly on the
B. Utilizing RFID Technology in Production and Supply dynamic behavior of VSM,where Solding and Gullander [8]
Chain Management tried to build a dynamic values stream mapping based on the
In supply chain and production activities the process starts simulation software called Simulation-Based Values Stream
with orders of raw materials and/or semi-finished parts from Mapping (SBVSM).
suppliers,which are then used by the sequential production Although many organizations implementing lean
processes in the manufacturing plant or product assembly concepts but they don't know how to keep and ensure them
line to make the finished products. However a manual data implemented on the production floor for long-term. Normally
entry and product identification processes for each single after the implementation of lean tools and measuring the
activity are time-consuming processes which delay the achieved results its needed a continuous monitoring system to
critical information necessary to run an efficient display the performance consistency of the production system,
manufacturing operation or warehouse/distribution. Small moreover to check and ensure the continuous implementation
gaps in timing or data entry errors can increase the difficult of lean tools to avoid degradation in implemented lean tools
task of ensuring the right product, at the right time, in the
and to measure the discrepancies and deviation between the
right place.
actual and target process which is called process compared to
Building a strong and robust supply chain management the Standard Work-in-Process (SWIP) required within the
system needs to develop an effective data collection and process.
information exchange methods especial in large scale In this paper it is proposed that the continuous real-time
enterprise cases. Depending of the described abilities of monitoring process of production performance can be
RFID technology which make it an ideal candidate for performed through DVSM, meanwhile RFID will give a
information capturing throughout the whole supply chain and real-time information live from production floor to the
the best method for data exchange between the supply chain already built VSM of the production floor ,referring to the
parties . In this manner there are absolutely many areas of the study of [12] the integration ofFRID in VSM to develop the
supply chain where RFID technology is utilized very
new tool DVSM will improve the performance level of the
effectively in order to optimize the supply chain process.
enterprise in three effecting level ; they are Automation ,
BMW and Vauxhall decided to utilize RFID technology,
Informatization and Transformation which in turn support the

118

Authorized licensed use limited to: UNIVERSITY PUTRA MALAYSIA. Downloaded on March 18,2021 at 06:02:41 UTC from IEEE Xplore. Restrictions apply.
deployment process of lean manufacturing tools and Sixth step: divide the production areas of the production
concepts in the enterprise . floor into Manufacturing cells or unit, then defme them with
specific code number; in order to facilitate that, the
B. Integration Development of RFID in VSM
manufacturing unit can be defmed with respect to the main
1) Framework Development of DVSM: The integration of workstation or machine exists at that area.
RFID in VSM will be built in steps as general as possible, so it
Seventh step: according to step six the objects and operators
can be easily adapted in any manufacturing environment, these
working in the divided units will be defmed according to their
steps are mentioned and explained below:
corresponding manufacturing unit, (the objects are used either
First step: attach each object in the production floor with by the main workstation directly or in the same area), while the
RFID - Tag either passive or active or chip - less or sensor tag idea behind this step is to support the lean tool 5S.
depending on the object tracking target. So every single object
Eighth step: determine the type of information which will
will be tagged and become so called smart-object in order to
be collected or updated at each manufacturing unit for each
interact with the continuous real-time monitoring and
object.
controlling system while flowing in the production stream.
Table 1 contains a proposal ofRFID objects tag structure. 2) The Principles of DVSM-Framework: The structure of

Second step: defme the added value activities through the framework is generally illustrated in figure 1, the flow

value stream which will be executed to produce the needed stream of value steam mapping is taken from Rother and shook
products according to customer specifications in order to build book "learning to see" [6], the working principles are
a standard production template. summarized in the following steps:

Third step: program the RFID-Tag attached to the semi­ First step: the working principle of the framework begin by
fmished product with the defmed added value activities as building the value stream mapping depending on the collected
standard operations and processing instructions for operators. information from the tagged objects in the existed value stream
in different time intervals under different manufacturing
Fourth step: determine the quality inspection point though condition, this will represent an actual situation of the
value stream to ensure if the semi-fmished products meet production through specific time intervals. Longer time
customer specifications and production standards so far as intervals give high accurate representation of the actual
well as to reduce the response time to changes in customers production behavioral. This step classified under automation
specifications during manufacturing if it not in advanced and Informatization according to [12].
production stages and can be adjusted.
Second step: use the built VSM as starting point to realize
Fifth step: build the needed middleware - software in order lean tools and concepts to improve the current value stream,
to analyzing and filtering the captured information and then re-engineer the value stream and make the needed

corresponded to each object with ability to share this transformation process according to lean tools and concepts
with help of continuous real-time information.
information with other departments through any information
network infrastructure.

TABLE 1. RADIO FREQUENCY IDENTIFICATION OBJECTS TAG STRUCTUR.

Object type Auto-ID Purpose of RFID utilizing Type of

content RFID-Tag

Workstations operators staff Staff -ID Attendance, location, time of coming and leaving, moving area.

Logistics operators staff Staff -ID Attendance, location, time of coming and leaving, moving area.

Sum the uptime and Idle period, downtime period, cycle time for each product
Workstation's Machines M -lO
arrival- departure of the products ,and condition update The Type of
RFID-Tag
Material handling systems and equipment MH-lO Sum the uptime and Idle time, downtime Period, capacity of product handling. depends on
the specific
Supporting equipment and tools SE/T-ID Usage time , condition updating target and
production
Semi-finished , subassemblies and finished Tracking, Tracing, Monitoring, Counting, time, Waiting, Status updating, environment
P-ID
products quality issues

Containers , boxes ,pallets and others C/BIP - ID Tracking, Tracing, Monitoring, Counting, Waiting

Other objects -------- -------------

119

Authorized licensed use limited to: UNIVERSITY PUTRA MALAYSIA. Downloaded on March 18,2021 at 06:02:41 UTC from IEEE Xplore. Restrictions apply.
 '
>
.
:
.

.
.
..
,..- .. ... .. .....
- . ." -

: : . . . . ..
\
�
,

'
li." I .
: : . , ,

i ISup , / .

:::
.
.

ii� /. 1j(..........'I.... � '-�

\\,
tl
"

",,,,
, ,2
·\.. Ka,.",
,'cr'!
�
.,
.

""
.
'--'
.
'-,- -- -

:
.

.5 :
,
----------f--------------------------
� -

-------------------- - -- ---- - -------------- - ----------- ------------------ f,

---

, 1

[: I II II II II Quality II I: !
I _________________________________________________________ •
'I I 1

Maintenalre Fmancial&Ac,coWlting Warehousing& Inventory ProductsDesign Personnel

::I II I I II I: !
I 1
: I
ProductionPlanning Sale.s&Marketmg Development& Re.search Logistic.s & Equipme.nt Purchasing
� ------------------------ [) -------------------------------

, ---------------- -- -------------------------- ,
I I

--- - --- - - J __ - ----- - - - - -- ------ - - --- - I RFID -Based Manufactu ring Ex e(.ution Sv ste.m - MES �- --- -- -- ---- - -------- - ---- - -- � - ---
t ______ ____ _____________ : ___________ J .

� o 0 0

,
,
T

Figure I: The Framework of DVSM.

Third step: after the implementation of re-engineering feedback to build a solutions in order to avoid the occurrence
process, the new value stream needs RFID as continuous of these errors and problems later, as well as RFID help us to
monitoring system which utilized for managing, supporting and fmd a new opportunities of improvement in our production
ensuring the lean tools and concepts like: managing TIT and systems for further performance improvements.
Kanban system, quality system, maintenance system,
supporting 5S concepts, work standardization, visual system,
3) The Impact of the DVSM on Lean Tool Implementation
line balancing, production smoothing, continuous and Waste Elimination: The DVSM has an important impact
improvement, small lot production and continuous flow. The on lean manufacturing implementation and contribution in
description of how RFID manage or support each one of these waste elimination; and how DVSM lead to real time
tools will be discussed later in farther separated research interaction between other departments and the current
papers. production situation in the production floor. Figure 2 shows a
proposed live interaction of ERP with RFID profitability
Forth step: using RFID system as continuous improvement
supporting tool, which is utilized to capture the often occurring through VSM to contribute in faster, easier, and cheaper waste
errors and problems; then the information will be used as a elimination.

120

Authorized licensed use limited to: UNIVERSITY PUTRA MALAYSIA. Downloaded on March 18,2021 at 06:02:41 UTC from IEEE Xplore. Restrictions apply.
 Figure 2: The impacts of using RFID on waste elimination and deploying lean manufacturing tools.

supports real-time manufacturing intelligence; where

V. CONCLUSION AND FUTURE WORK manufacturers can achieve high levels of performance. For
Due to the importance of value stream mapping in lean further research in this topic we will try to build a general
manufacturing, which is used as starting point, identification framework showing how DVSM will manage many lean tools
tool and roadmap to use the needed lean manufacturing tools in the companies like KANABAN, Bullwhip effects, TPM,
and principle in the production system , in this work the supporting cost accounting and other areas.
effectiveness of this powerful tool was improved and
developed through integrating RFID system in VSM as real­ REFERENCES

Womack, 1. P., Jones, D. T. and Roos, D. "The Machine that changed

time data collecting technology , the real-time data enables
[I]
VSM to represents the exact situation in the production the world". Rawson Associates. New York. USA, 1990.
floor, the exact representation for the production floor will [2] Liker, J. K. "The Toyota Way". McGraw-Hill. New York. USA, 2004.
Bozzone, V.
help the value stream manager to make the right decisions
[3] "Speed to Market". AMACOM, New York, NY, 2002.
during and after lean implementation process , the new 2002
developed system called DVSM will helps the companies after [4] Edwards, D. K. "Practical guidelines for lean manufacturing
adopting lean to ensure the implementation of each planned equipment". Production & Inventory Management Journal 37, (2), 51-
and scheduled process as well as measure the discrepancies 55, 1996.1996
and deviation between the actual and standard process . The [5] Feld, W. M. "Lean Manufacturing: Tools, Techniques, and How to Use
continuous real-time collected data are forwarded to different Them". Sf. Lucie Press, New York, NY. , 2001.

departments for different purposes as mentioned above. DVSM

121

Authorized licensed use limited to: UNIVERSITY PUTRA MALAYSIA. Downloaded on March 18,2021 at 06:02:41 UTC from IEEE Xplore. Restrictions apply.
[6] Rother, M. and Shook, 1. "Learning to See." The Lean Enterprise [10] Brewer and Landers 1997 A. Brewer and T.L. Landers. "Radio
Institute, Brookline, MA. ,2003. frequency identification: A survey and assessment of the technology.

[7] Storch, R.L. and Lim, S. "Improving flow to achieve lean Tech. rep., University of Arkansas, Fayetteville, Arkansas, USA, 1997.

manufacturing in shipbuilding". Production Planning and Control 10, [II] Hunt, V.D., Puglia, A., Puglia, M. "RFID-A Guide to Radio Frequency
(2), 127-137, 1999. Identification", Wiley-Interscience ,2007.

[8] P. Solding and P. Gullander "Concepts for simulation based value [12] T. Faupel ,J. Strueker and D. Gille "Performance Improvements Based
stream mapping" Proceedings of the Winter Simulation Conference, PP on RFID - Empirical Findings from a Cross-Sectional Study".
2231-2237, 2009. Proceedings of the Fourteenth Americas Conference on Information

[9] Z. Asif and M. Mandviwalla " Integrating the Supply Chain with RFID: Systems, Toronto, ON, Canada August 14th -17th , 2008.

ATechnical and Business Analysis" Communications of the Association

for Information Systems (Volume 15, 393-427) 2005.

122

Authorized licensed use limited to: UNIVERSITY PUTRA MALAYSIA. Downloaded on March 18,2021 at 06:02:41 UTC from IEEE Xplore. Restrictions apply.