Paper Contents
Abstract
Manufacturing systems today are challenged by the increasing demand for high product variety, shorter delivery cycles, and lower operational costs. In this context, Lean Manufacturing has emerged as a strategic approach to eliminating non-value-added activities and improving flow efficiency. However, implementing lean tools on the shop floor without prior validation can lead to costly disruptions. This review paper investigates the integration of Value Stream Mapping (VSM) and MATLAB-based simulation as a powerful method to test, validate, and optimize lean practicesparticularly aimed at reducing lead time in assembly line environments.The review explores how tools such as Kanban, SMED, TPM, and Standardized Work can be digitally modeled and evaluated using MATLAB SimEvents. The simulation framework allows real-time analysis of production metrics, such as WIP, lead time, cycle time, and throughput, before physical implementation. By referencing key academic studies and industrial applications, this paper illustrates the measurable benefits of simulation-backed lean transformation and highlights how simulation enables the identification of bottlenecks, workload imbalances, and process variability.While the advantages are significant, challenges such as data accuracy, model complexity, and organizational resistance are also discussed. The paper identifies future research opportunities, including real-time simulation integration, optimization through artificial intelligence, and the inclusion of sustainability metrics.Overall, this review establishes that combining Lean Manufacturing with simulation not only enhances decision-making but also builds a structured, low-risk path toward operational excellence and continuous improvement in manufacturing systems
Copyright
Copyright © 2025 Yadav Manish Krishnaprasad. This is an open access article distributed under the Creative Commons Attribution License.
