Improving Manufacturing Line Design Efficiency Using Digital Value Stream Mapping

This study proposes a real-time data-based Digital Value Stream Mapping (Digital VSM) framework that integrates Artificial Intelligence (AI) feature selection and discrete-event simulation validation to enhance production system performance. Unlike conventional VSM approaches that rely on static, manually aggregated data, the proposed framework uses real-time operational data to dynamically quantify Value Added (VA), Non-Value Added (NVA), and Necessary Non-Value Added (NNVA) activities. To improve decision accuracy, an Artificial Neural Network (ANN) combined with Genetic Algorithm (GA) feature selection is employed to identify dominant production variables influencing lead time and line imbalance. Furthermore, Ranked Positional Weight (RPW) optimization results are validated through Tecnomatix Plant Simulation to ensure robustness before physical implementation. The proposed framework was applied to a discrete manufacturing line, resulting in a reduction of total lead time from 8755 s to 6400 s and an increase in process ratio from 33.64% to 45.91%, with line efficiency reaching 91.7%. The findings demonstrate that integrating Digital VSM with AI-driven feature selection and simulation validation transforms Lean analysis from a descriptive tool into a predictive and validated decision-support system suitable for Industry 4.0 environments.