View in EDS HTML Full Text PDF Full Text

Real-time shop floor operations improvement based on dynamic value stream mapping and hybrid simulation in Industry 4.0: an economic perspective.

Saved in:
Bibliographic Details
Title: Real-time shop floor operations improvement based on dynamic value stream mapping and hybrid simulation in Industry 4.0: an economic perspective.
Authors: Liu, Mingzhou1 (AUTHOR), Sun, Mengyuan1 (AUTHOR), Zhang, Xi1 (AUTHOR) zhang_xi@hfut.edu.cn, Ge, Maogen1 (AUTHOR), Hu, Jing1 (AUTHOR)
Source: International Journal of Production Research. Sep2025, Vol. 63 Issue 18, p6776-6800. 25p.
Subjects: Value stream mapping, Industry 4.0, Waste minimization, Real-time computing, Process optimization, Flexible manufacturing systems, Economic impact analysis, Hybrid computer simulation
Abstract: With increased market competition and the development of Industry 4.0, production operations is being driven towards increased flexibility. Multi-product flow and variable production processes on the shop floor complicate waste identification, analysis, and reduction. To continuously improve based on real-time information in dynamic production processes, this paper proposes an integrated approach of dynamic value stream mapping and hybrid simulation(DVSM-HS). The dynamic value stream mapping(DVSM) is extended from time temporal and economic dimensions respectively to decompose and integrate work-in-process sequences and processes. A dynamic cost model is constructed based on time-driven activity-based costing to extract the variable costs of production resources. By combining hybrid simulation of discrete events and system dynamics, variations in multi-product flows are captured and mapped, and their economic impact over time is quantified. A case study in an automotive painting workshop demonstrates the practical application of waste reduction and decision-making across different scenarios. The results show that the proposed DVSM-HS can address process variability by identifying the temporal and spatial characteristics of waste. Based on waste localisation and economic evaluation, this study supports managers diagnose problems and conduct Lean improvements in real-time operations, optimising resource and capability allocation to enhance production profitability. [ABSTRACT FROM AUTHOR]
Copyright of International Journal of Production Research is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract. (Copyright applies to all Abstracts.)
Database: Engineering Source
Full text is not displayed to guests.
FullText Links:
  – Type: pdflink
Text:
  Availability: 1
Header DbId: egs
DbLabel: Engineering Source
An: 187749446
AccessLevel: 6
PubType: Academic Journal
PubTypeId: academicJournal
PreciseRelevancyScore: 0
IllustrationInfo
Items – Name: Title
  Label: Title
  Group: Ti
  Data: Real-time shop floor operations improvement based on dynamic value stream mapping and hybrid simulation in Industry 4.0: an economic perspective.
– Name: Author
  Label: Authors
  Group: Au
  Data: <searchLink fieldCode="AR" term="%22Liu%2C+Mingzhou%22">Liu, Mingzhou</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Sun%2C+Mengyuan%22">Sun, Mengyuan</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Zhang%2C+Xi%22">Zhang, Xi</searchLink><relatesTo>1</relatesTo> (AUTHOR)<i> zhang_xi@hfut.edu.cn</i><br /><searchLink fieldCode="AR" term="%22Ge%2C+Maogen%22">Ge, Maogen</searchLink><relatesTo>1</relatesTo> (AUTHOR)<br /><searchLink fieldCode="AR" term="%22Hu%2C+Jing%22">Hu, Jing</searchLink><relatesTo>1</relatesTo> (AUTHOR)
– Name: TitleSource
  Label: Source
  Group: Src
  Data: <searchLink fieldCode="JN" term="%22International+Journal+of+Production+Research%22">International Journal of Production Research</searchLink>. Sep2025, Vol. 63 Issue 18, p6776-6800. 25p.
– Name: Subject
  Label: Subjects
  Group: Su
  Data: <searchLink fieldCode="DE" term="%22Value+stream+mapping%22">Value stream mapping</searchLink><br /><searchLink fieldCode="DE" term="%22Industry+4%2E0%22">Industry 4.0</searchLink><br /><searchLink fieldCode="DE" term="%22Waste+minimization%22">Waste minimization</searchLink><br /><searchLink fieldCode="DE" term="%22Real-time+computing%22">Real-time computing</searchLink><br /><searchLink fieldCode="DE" term="%22Process+optimization%22">Process optimization</searchLink><br /><searchLink fieldCode="DE" term="%22Flexible+manufacturing+systems%22">Flexible manufacturing systems</searchLink><br /><searchLink fieldCode="DE" term="%22Economic+impact+analysis%22">Economic impact analysis</searchLink><br /><searchLink fieldCode="DE" term="%22Hybrid+computer+simulation%22">Hybrid computer simulation</searchLink>
– Name: Abstract
  Label: Abstract
  Group: Ab
  Data: With increased market competition and the development of Industry 4.0, production operations is being driven towards increased flexibility. Multi-product flow and variable production processes on the shop floor complicate waste identification, analysis, and reduction. To continuously improve based on real-time information in dynamic production processes, this paper proposes an integrated approach of dynamic value stream mapping and hybrid simulation(DVSM-HS). The dynamic value stream mapping(DVSM) is extended from time temporal and economic dimensions respectively to decompose and integrate work-in-process sequences and processes. A dynamic cost model is constructed based on time-driven activity-based costing to extract the variable costs of production resources. By combining hybrid simulation of discrete events and system dynamics, variations in multi-product flows are captured and mapped, and their economic impact over time is quantified. A case study in an automotive painting workshop demonstrates the practical application of waste reduction and decision-making across different scenarios. The results show that the proposed DVSM-HS can address process variability by identifying the temporal and spatial characteristics of waste. Based on waste localisation and economic evaluation, this study supports managers diagnose problems and conduct Lean improvements in real-time operations, optimising resource and capability allocation to enhance production profitability. [ABSTRACT FROM AUTHOR]
– Name: AbstractSuppliedCopyright
  Label:
  Group: Ab
  Data: <i>Copyright of International Journal of Production Research is the property of Taylor & Francis Ltd and its content may not be copied or emailed to multiple sites without the copyright holder's express written permission. Additionally, content may not be used with any artificial intelligence tools or machine learning technologies. However, users may print, download, or email articles for individual use. This abstract may be abridged. No warranty is given about the accuracy of the copy. Users should refer to the original published version of the material for the full abstract.</i> (Copyright applies to all Abstracts.)
PLink https://search.ebscohost.com/login.aspx?direct=true&site=eds-live&db=egs&AN=187749446
RecordInfo BibRecord:
  BibEntity:
    Identifiers:
      – Type: doi
        Value: 10.1080/00207543.2025.2487921
    Languages:
      – Code: eng
        Text: English
    PhysicalDescription:
      Pagination:
        PageCount: 25
        StartPage: 6776
    Subjects:
      – SubjectFull: Value stream mapping
        Type: general
      – SubjectFull: Industry 4.0
        Type: general
      – SubjectFull: Waste minimization
        Type: general
      – SubjectFull: Real-time computing
        Type: general
      – SubjectFull: Process optimization
        Type: general
      – SubjectFull: Flexible manufacturing systems
        Type: general
      – SubjectFull: Economic impact analysis
        Type: general
      – SubjectFull: Hybrid computer simulation
        Type: general
    Titles:
      – TitleFull: Real-time shop floor operations improvement based on dynamic value stream mapping and hybrid simulation in Industry 4.0: an economic perspective.
        Type: main
  BibRelationships:
    HasContributorRelationships:
      – PersonEntity:
          Name:
            NameFull: Liu, Mingzhou
      – PersonEntity:
          Name:
            NameFull: Sun, Mengyuan
      – PersonEntity:
          Name:
            NameFull: Zhang, Xi
      – PersonEntity:
          Name:
            NameFull: Ge, Maogen
      – PersonEntity:
          Name:
            NameFull: Hu, Jing
    IsPartOfRelationships:
      – BibEntity:
          Dates:
            – D: 15
              M: 09
              Text: Sep2025
              Type: published
              Y: 2025
          Identifiers:
            – Type: issn-print
              Value: 00207543
          Numbering:
            – Type: volume
              Value: 63
            – Type: issue
              Value: 18
          Titles:
            – TitleFull: International Journal of Production Research
              Type: main
ResultId 1