Mapping Value to Reduce Waste in Chaotic Industrial Stream

Implementing lean production principles in industrial processing units has a direct and significant impact on improving their competitive position and profitability. By reducing production time, achieved through minimizing hidden and apparent losses and streamlining workflows, these units gain valuable time and resources while indirectly lowering product costs. This study aims to identify opportunities for process improvement and optimization in the advancing section of a mineral processing facility using the value stream mapping (VSM) method. A VSM utilizing lean production tools was then designed to address these inefficiencies. This quantitative research collected data through field measurements, recording the time required for each action from start to finish within the advancing section. Through brainstorming sessions and group discussions with relevant experts, a process map was created and analyzed, and waste sources were identified. The results indicated that the average total cycle time for the advancing section was 852 minutes, with 390 minutes attributed to waiting waste, comprising over 45% of the total cycle time. After identifying the waste sources, appropriate solutions were proposed. The study concludes that lean production is a practical approach for analyzing processes, enhancing efficiency, reducing waiting times, and maximizing value to improve process flow.