Analyze the Value Stream Mapping for Lead Time Reduction by Lean: A Review (original) (raw)
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Establish the Value Stream Mapping For Lead Time Evaluation by Lean Concept
Toyota started practicing TPS (Toyota Production System) since 1950 successfully. Due to success of TPS Many companies across the world stated using the same. Later in 1990s. M. Womak and Jones gave the name it as a lean manufacturing. Lean manufacturing is now one of the most powerful manufacturing systems in the Competitive world. Numerous organizations around the world have implemented and adopted it to enhance their productivity through reduction and elimination of Waste. This project reports is on understanding and implementation of one of the Lean tools which is; Value Stream Mapping, for Directional Control Valve in Bosch Rexroth (India) Pvt. Ltd. – Sanand Plant, Ahmedabad. Value Stream Mapping is a lean tool to identify the value added and non-value added activity during the production. Using this, identify the Waste and removing it along the processes which is based on the principle of Bosch Production System. (TPS – Toyota Production System) This intends the checking of the Inventory level during the process of Manufacturing and Assembling of the products.
For the last few years almost every manufacturing industry has been trying to get 'lean'. A headlong rush to offer value to the customers by becoming lean and responsive has created an urgency for researchers and practitioners to apply new tools and techniques to address various wastes. The process of mapping the material and information flows of all components and sub-assemblies in a value stream that includes manufacturing, suppliers and distribution to the customer is known as value stream mapping (VSM). VSM has proved effective in identifying and eliminating wastes in a facility with similar or identical product routings, such as in assembly facilities. In this paper, an attempt has been made to use VSM as a technique to achieve productivity improvement at supplier end for an auto industry. Both current and future ('as is' and 'to be') states of supplier shopfloor scenarios are discussed using value stream concepts. This is analysed along with takt time calculations and the application of other gap areas. Finally, gain in production output per person, reduction of work in process and finished goods inventory affecting productivity are also reported.
International Journal of Engineering Research and Advanced Technology (IJERAT), 2020
Every company, especially manufacturing companies are required to make efficiency in each line to increase productivity in order to compete with other companies. With the increasing demand for new products from customers, or usually called a New Project, companies are challenged to utilize the work area as much as possible with the existence of new production lines to meet the customer's demand. To do that, the company should immediately make improvements on all lines so that free space will be obtained which will be used for new projects. To reduce the Lead Time on the line in the production department with the expectation to get an optimal working area which creating space to be used for a New Project. Using the Value Stream Mapping method as a first step to mapping the entire process from upstream to downstream to identify Lead Time and lead to waste in each process. High waste occurs in the inventory lead time. Non-value added activities are mostly found in the inventory part after platting in receiving and finished good parts. It also found in the information flow of the finished good parts. While developing the future state map, it decreased the total lead time by about 5% so that it creating a workspace for the new projects.
Lean Manufacturing: Waste Reduction Using Value Stream Mapping
E3S web of conferences, 2018
Cristal Sri Sujarwati is a small medium enterprise (SME) that produce keripik salak in Sleman, Yogyakarta. To survive and win industrial competition, Cristal Sri Sujarwati was required to improve its performance. But in reality there was a lot of waste in order fulfillment processes marked by ineffective and inefficient work. In this research, lean manufacturing aims to identify and eliminate waste so that the company could improve its performance in winning the industry competition. Lean manufacturing is a systematic approach used to identify and eliminate waste. This lean concept could improve responsiveness through waste reduction, continuous improvement and cost reduction. In order to identify and eliminating waste, a value stream mapping tools, waste weighting questionnaire, value stream analysis tools, and fishbone diagram are used. From the results of research, the dominant waste in the production process was waste defects, waiting, and unnecessary inventory. To eliminate waste, process activity mapping (PAM), the one of detailed mapping tools in VALSAT are used. From the results of the improvement recommendations analysis, lead time decreased by 80 minutes. From the analysis using PAM, there was a reduction of NVA activity from 3.10% to 1.01%.
Studies on applications of lean in a continuous process industry are limited. There is lot of opportunities for improvement in the process industries. If lean tools are utilized This paper addresses the application of Value Stream Mapping as one of the Lean tools to eliminate waste, and improved operational procedures and productivity. Current state map is prepared and analyzed and suggested to improve the operational process. Accordingly the future state map is drawn. The study reveals that there is an improvement in the tact time by implementing the proposed changes if incorporated in the future state map. A value stream map takes into account not only the activity of the product, but the management and information systems that support the basic process. This is especially helpful when working to reduce cycle time, because you gain insight into the decision making flow in addition to the process flow. It is actually a Lean tool. Studies on applications of lean in a continuous proc...
Application of lean manufacturing using value stream mapping in an auto‐parts manufacturing unit
Journal of Advances in Management Research, 2013
Purpose -This paper addresses the application of lean manufacturing using value stream mapping (VSM) concepts in an auto-parts manufacturing organization. Using value stream concepts, both current and future states maps of the organization's shop floor scenarios have been discussed to identify sources of waste between the existing state and the proposed state of the selected organization for improving its competitiveness. Design/methodology/approach -VSM process symbols have been used to discuss lean implementation stages in the auto-parts manufacturing unit. Current states of the selected manufacturing unit have been prepared with the help of VSM symbols and improvement areas have been identified. Few modifications in current state have been made and with these modifications, a future state map is suggested. Findings -After comparison of the current and future states of the selected manufacturing unit, it has been found that 69.41% reduction in cycle time, 18.26% reduction in work inprocess inventory and 24.56% reduction in production lead times for Replacement Ball product. While for Weldon Ball End product, 51.87% reduction in cycle time, 21.51% reduction in work in-process inventory, 25.88% reduction in lead time has been noted. Research limitations/implications -The findings of this case study are valid due to limited selection of products only. Originality/value -This paper depicts the true picture of implementation of lean manufacturing tools in an organization.
Lean Manufacturing Machine using Value Stream Mapping
1st International Conference on Advance and Scientific Innovation (ICASI), 2019
Production process of mid scale manufacturing in Indonesia commonly using conventional sequential process. There are some wasted process and has already slowing down production lead time and creating more expenses for manufacture. The need of eliminating useless steps in production development for cost cutting lead to Value Stream Mapping (VSM) as mapping tool in it. VSM acceptance itself has already proven in many research studies which use manufacture in many levels as its case study. This paper, aims at using VSM as tool in examining mid scale manufacture production development. It also evaluated how VSM is put into real world practice in mid scale manufacture in Indonesia. Based upon observation and interview, then it can create future state map which eliminate waste from production development and also shorten lead time and propose new production development flow. At least, more than 500 minutes overall which can be eliminated in production process time after remapping it. While at least 141 minutes are being reduced for its VAT. However, it still need non technical effort to ensure company to use available map in their production development. Since that mostly mid scale manufacturing using family business management which still believe traditional process rather than modern one. Thus, future research should include psychological industrial aspect in VSM implementation in Indonesia
Nirma University Journal of Engineering and Technology, 2016
Lean manufacturing deals with a manufacturing process improvement based on the fundamental goal of Toyota production system in order to minimize or eliminate waste while maximizing production flow. Today in a highly competitive local and global market, it is very much crucial to satisfy the changing demand of the customers. Thus, in today’s manufacturing industry there is an increased focus to produce the right product at right time. The prime objective of this paper to apply a significant lean manufacturing tool know as Value Stream Mapping (VSM). To fulfil this objective a fundamental principles of lean were implemented and VSM was generated to analyse the production flow at an automotive industry and improve the current operating condition to overcome the difficulties with current state of work through time study, Takt time calculation, modifying work cell layout. And based on the future state of VSM, final results showed that by implementing this lean techniques, Production Lead...
Lean Manufacturing Implementation Through Value Stream Mapping: A Case Study
Jurnal Teknologi, 2014
Lean Manufacturing (LM) is a business strategy that was developed in Japan. The main contribution of lean manufacturing is the identification and elimination of waste. Companies apply LM to sustain their competitiveness over their competitors by improving the manufacturing system’s productivity and quality enhancement of the product. The goal of this paper is to apply one of the most significant lean manufacturing techniques called Value Stream Mapping (VSM) to improve the production line of a company that produces several components for vehicle assembly line by decreasing the waste and non-value added activities. First, the current value stream map of production line was developed using personal interviews, observations and secondary data of the company. Subsequently, the future value stream map was proposed based on the lean manufacturing principles to improve total production lead time and value added time. Based on the final result it can be concluded that VSM is a useful and a...