APPLICATION OF VALUE STREAM MAPPING TOOL TO REDUCE WASTES IN BEARING INDUSTRY (original) (raw)
Related papers
Manufacturers always face cost-reduction and efficiency challenges in their operations. Industries require improvement in Production Lead Times, costs and customer service levels to survive. Because of this, companies have become more customers focused. The result is that companies have been putting in significant effort to improve their efficiency. In this paper Value Stream Mapping (VSM) tool is used in bearing manufacturing industry by focusing both on processes and their cycle times for a product UC-208 INNER which is used in plumber block. In order to use the value stream mapping, relevant data has been collected and analyzed. After collecting the data customer need was identified. Current state map was draw by defining the resources and activities needed to manufacture, deliver the product. The study of current state map shows the areas for improvement and identifying the different types of wastes. From the current state map, it was noticeable that Annealing and CNC Machining processing have higher cycle time and work in process. The lean principles and techniques implemented or suggested and future state map was created and the total lead time was reduced from 7.3 days to 3.8 days. The WIP at each work station has also been reduced. The production lead time was reduced from 409 seconds to 344 seconds.
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 value stream mapping (VSM) in gear manufacturing process: A case study
2018
Since the end of 20th century, Lean Manufacturing has been recognized as an important approach in competitive industrial environments to improving productivity by reducing process cycle time. To remain competitive in the market, organizations are compelled to find new domains for improvements in order to reduce production lead time and to smooth the flow of processes. The current research aims at designing efficient future VSM to improve productivity by reducing process cycle time and waste in a gear manufacturing process in an automotive industry. The approach was based on mapping the current state of the process to identify the non-value-added activities and also for opportunities for improvement in value added activities. Kaizen events are the main metrics for improvement in the current process by integrating it with the future value stream map. This study concluded that the designed future value stream map helps effectively in identifying the wasteful activities i.e. distance tr...
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.
APPLICATION OF VALUE STREAM MAPPING IN BHUJIA MANUFACTURING
Value stream mapping is an enterprise improvement tool to help in visualizing the entire production process, representing both material and information flow. A value stream is all the actions (both value added and non-value added) required to bring a product through the main flows essential to every product for the production flow from raw material into the arms of the customer. Value stream mapping (VSM) is a tool of lean manufacturing. The ultimate goal of Value stream mapping is to identify all types of waste in the value stream and to take steps to try and eliminate these. In the present research paper, a food industry (Bhujia manufacturing industry) have been considered with current state maps and future state maps after following the different steps starting from the detailed time study for mapping the processes from raw materials to final product. Value stream mapping captures the information at individual's stations about cycle time, set up time, WIP (Work in Process) inventory, manpower requirement and the information flow from raw materials to final product. The overall non value added time is reduced during Bhujia manufacturing process.
IJERT-Improvement of Manufacturing Production Process using Quality Value Stream Mapping
International Journal of Engineering Research and Technology (IJERT), 2015
https://www.ijert.org/improvement-of-manufacturing-production-process-using-quality-value-stream-mapping https://www.ijert.org/research/improvement-of-manufacturing-production-process-using-quality-value-stream-mapping-IJERTV4IS060284.pdf In this research work is to develop a quality value stream mapping (Q-VSM) for a production in a heavy transformer manufacturing company in India. The process begins with creating a current state map (CSM) and understands the production flow and the current cycle times. This provides the current information needed to produce a future state map (FSM). The goal is to identify and eliminate the waste, and non-added materials which is any activity that does not add value to the final manufacturing product, in the production process of the company. To collect the information needed, the study was conducted within the manufacturing production facility to enable the researcher gained knowledge and familiarized with the production flow and the activities being performed at the shop floor of the company. Parameters such as working time, cycle times, brake down times, and work in process for inventory and manufacturing materials, and information flow paths were recorded. High performance computer based "ARENA" simulation software was used to simulate and analyze the process flow and working process times. Result from the analysis shows that there are areas where the company can further improve their Manufacturing Production System (MPS). The results show the improvement of the manufacturing efficiency up to 64% based on the new proposed arrangement of the layout. Therefore propose of shop floor layout will be guided to the company in order to improve their manufacturing production system.
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.