SimLean: a reference framework for embedding simulation in lean projects

The intense global competition in today’s market is forcing organisations to looking for good process improvement techniques constantly. Currently lean methodology is one of the most popular programs for process improvement. However, the static lean tools have caused problems in lean implementation. The main aim of the research work is to develop a reference framework about embedding simulation in lean projects. By embedding simulation method in lean projects, deficiencies of static lean tools such as their inability to assess the effects of variation, to validate effects of proposed changes before implementation, to identify other possible improvements or to capture the interactions between system components (Standridge and Marvel, 2006) might be overcome. A combination of research methodology approaches is adopted. This includes conducting literature review, observing companies’ practices and interviewing experts, and adopting several case studies. The focal points of the reference framework are designed in the preimplementation stage of lean projects. Referring to the detailed implementation of the framework, a new modelling environment is proposed. This new environment will use customised VSM templates built in Microsoft Visio software and in Arena simulation system respectively to achieve the quick modelling for lean projects. The proposed modelling environment is validated through five case studies. The main features of the proposed framework are summarized as systematic, generic and the ability to overcome major challenges. A major contribution of the developed system is its ability to simplify, facilitate and standardize simulation modelling in lean projects. It dramatically reduces building blocks in the model, saves model constructing time and eliminates errors in logic design; the simulation models provides better results than static VSM; meanwhile, the interface between Arena and Visio greatly reduces users’ fear for complex simulation modelling environment, and increases the ease of use.