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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...
Reducing Work in Progress Inventory in a Valve Industry Using Value Stream Mapping
In this paper Value Stream Mapping (VSM) tool is used in valve manufacturing industry by focusing both on processes and their cycle times for a product 3/4 bonnet valve. 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. In this Process (current state) it is noticeable that it is a batch flow and WIP is in the form of machine availability and customer demand time.
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.
One of the most important economic sectors contributing to the industrial growth in Vietnam is aquatic products processing industry, especially focusing on the seafood export as shrimp. More and more Vietnamese companies have applied Lean manufacturing to enhance the product quality and to reduce the production cost, which is called non-value activities for the system production. The aim of this paper is to implement Value Stream Mapping (VSM) in production line at Ocean Shine Company, a fundamental tool of Lean manufacturing that involves constructing an overview of the whole production system and identifying wastes. As a result, some suggestions supporting to reduce wastes and inventory time of the value stream production line will be applied in the short term. Focusing on the current and the future state value stream mapping was established. In addition, ARENA software has been used to build two simulation models based on two VSMs. The application results in the enterprise are also presented specifically.
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...
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.
World Journal of Advanced Engineering Technology and Sciences, 2024
This paper focuses on the application of Value Stream Mapping (VSM) within the context of the electronics manufacturing industry, aiming to improve its operational efficiency and financial performance. The study thoroughly analyzes costs, integrating VSM to justify economic benefits. Data was collected directly from the manufacturing floor to create a current state map, enabling the identification of non-value-added activities and sources of waste. Areas for potential improvement were pinpointed to reduce or eliminate these inefficiencies. By implementing these proposed enhancements, the paper outlines a future state map for the electronics manufacturing process and presents the results of applying Value Stream Mapping. Comparing the current and future state maps, the study reveals that embracing Lean principles, in conjunction with Value Stream Mapping, can significantly benefit the electronics manufacturing industry. Specifically, it can reduce production lead times by 67.84% and decrease costs by 8.69%. This research underscores the financial implications of adopting Value Stream Mapping, illustrating that by combining Lean principles with VSM, industries can offer rapid customer responses at lower costs, a crucial factor for improving competitive performance in the existing market landscape.
Production Flow Analysis through Value Stream Mapping: A Lean Manufacturing Process Case Study
Click 'Lean'' approach has been applied more than frequent in many manufacturing management floors over these few decades. Started in the automotive industry, sequential improvement initiatives were implemented to enhance the manufacturing practice changes. The team described a case where Lean Production (LP) principles were adapted for the process sector of an automotive part manufacturing plant. Value Stream Mapping (VSM) is one of the key lean tools used to identify the opportunities for various lean techniques. The contrast of the before and after the LP initiatives in determine managers potential benefits such as reduced production lead-time and lower work-in-process inventory. As VSM involves in all of the process steps, both value added and non-value added, are analyzed and using VSM as a visual tool to help see the hidden waste and sources of waste. A Current State Map is drawn to document how things actually operated on the production floor. Then, a Future State Map is developed to design a lean process flow through the elimination of the root causes of waste and through process improvements. An Implementation Plan then outline details of the steps needed to support the LP objectives. This paper demonstrates the VSM techniques and discusses the application in an LP initiative on a product (Front disc, D45T) case study.