Identifying Inefficiencies in Towel Pan Production Through Value Stream Mapping

Abstract

In modern industrial facilities optimizing production lines is essential for improving efficiency and minimizing waste. This study presents an original application of Value Stream Mapping (VSM) combined with Arena simulation to identify and address inefficiencies in a towel pan manufacturing facility—a previously unexplored context in Lean Manufacturing research. By mapping the current state and simulating workflows the research uncovers critical bottlenecks excessive waiting times and resource allocation imbalances while introducing two key contributions: (1) a hybrid VSM-simulation methodology to validate process improvements in thermal comfort product manufacturing bridging gaps in low-volume production systems and (2) data-driven Kaizen bursts targeting non-value-added activities (NVAs) such as manual Kanban systems and material handling inefficiencies. These findings advance both theory and practice by demonstrating VSM’s adaptability to complex low-volume environments and providing actionable Lean insights ultimately underscoring the role of systematic diagnostics and simulation as pivotal tools for sustainable process optimization. © 2025 Elsevier B.V. All rights reserved.