Anpassning av VSM i en ETO-produktion : En fallstudie på Aiab energy

Sammanfattning

This study addresses the challenges of applying value stream mapping in an engineer-to-order (ETO) environment. Traditional VSM is developed for stable production environments with high volumes and low variation, which creates limitations in environments marked by high variability, complex flows and information dependencies. The purpose of this study is to investigate how an adapted VSM can be used as an improvement tool to enhance lead time, planning stability and coordination within an ETO environment. The study was conducted as a case study at Aiab energy in combination with action research. Based on a theoretical framework, a method was developed that includes a two-dimensional CODP, methods for managing nonlinear flows and capacity-based order release through Paired-cell Overlapping Loops of Cards with Authorization (POLCA). The results show that a strategic relocation of the CODP allows for parallel work to occur between production and engineering, which reduces lead time and information dependencies. Furthermore, replacing traditional inventory signals, such as kanban, with POLCA loops creates a theoretically more stable flow that improves planning stability. The analysis of the future state map indicates that the total lead time can theoretically be reduced by about 40%, where the greatest improvements are achieved through reduced intermediate inventory and the relocation of the CODP. The study demonstrates that VSM can be applied in ETO environments if the method is adapted to variation and information flows. The result further indicates that the future state map should primarily be used as a visual and diagnostic support tool rather than as an exact control model for improvement work.