Development of a multi-product cost and value stream modelling methodology

In support of the life-cycle engineering of manufacturing enterprises (MEs), there is a need to provide reusable computational representations of organisational structures, processes, information, resources, and related cost and value flows. Current best process mapping techniques do not suitably capture key time-based attributes of ME systems, particularly with respect to the dynamics associated with multi-product work flows through shared resource systems. However, multiple work-flow dynamics will likely impact significantly on cost and value generation, and if this kind of dynamics cannot be effectively modelled, the use of process mapping will be limited as a basis for decision-making. Therefore, this paper presents an integrated multi-product dynamic cost and value stream modelling methodology with the embedded capability of capturing aspects of dynamics associated with multiple product realisations in MEs. The first part of the research presented in this paper shows the application of an enhanced and integrated use of process mapping and enterprise modelling techniques in a case study involving a POP manufacturing company in the UK. When compared with the use of current lean-based value-stream-mapping techniques, case study results obtained when using the first part of the modelling method have led to improved solutions to problems of: analysing and estimating cost and values; and improving the design and operation of multi-product realising systems.