Low density polyethylene back application of leanmanufacturing techniques to transformation processes:Value flow mapping approach

Today's competitive conditions require businesses to be customer-oriented to sustain their existence. Competition necessitates embracing innovation, change, and continuous improvement, demanding dynamism. Consequently, businesses strive to shape their production in line with systems that adapt to competitive conditions. Lean production systems, which support these objectives, are value-oriented systems aiming for continuous improvement in production. This study aims to investigate the concept of value stream mapping within the scope of lean production and to evaluate the results by applying value stream mapping to low-density polyethylene recycling processes. Based on this data, the study intends to draw a future state map after analyzing the current state of the business and the outcomes of planned improvement efforts, thus implementing necessary improvements using lean production techniques. In the application section of this study, value stream mapping is utilized in a business facing issues such as difficulties in timely order preparation, high production errors, and low production line efficiency, to identify waste sources and reveal both known and unknown wastes. This method helps in pinpointing the problem areas and finding potential solutions for improvement using lean production techniques. Accordingly, a value stream mapping study was conducted in a plastic sector company producing granule raw materials. The production process includes activities in the Pre-Preparation Line, Granule Extrusion Line, Film Extrusion Line, and Film Cutting Machine. The company operates 6 working days per week, 3 shifts per day, 8 hours per shift, with a daily net working time of 22.5 hours, and a weekly production amount observed to be 33,750 kg. Based on this fundamental information, improvement scenarios and the future state map are developed. This study aims to prevent potential errors in low-density polyethylene recycling processes and contribute to meeting competitive conditions by providing necessary solutions.