A REAL-TIME APPROACH TO WASTE QUANTIFICATION: IMPLEMENTING DYNAMIC VALUE STREAM MAPPING (DVSM) USING INDUSTRIAL IOT DATA

Abstract

The convergence of Lean Manufacturing and Industry 4.0 necessitates advanced tools to manage increasing system complexity. This paper addresses the critical limitation of traditional Value Stream Mapping (VSM)—its static, retrospective nature—by proposing and validating a novel four-stage Dynamic Value Stream Mapping (DVSM) Integration Framework that utilizes Industrial Internet of Things (IIoT) data. The framework systematically maps IIoT sensor outputs to key Lean performance metrics, enabling real-time visualization of process waste. Through a comparative case study, DVSM was empirically shown to reveal 35.0 hours of previously hidden non-value-added (NVA) time over a one-week period. This research provides a validated, practical roadmap for organizations seeking to achieve data-driven continuous improvement and realize the potential of Lean Smart Manufacturing.