Effects of Value Stream Mapping in a Processing Industry (original) (raw)
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Journal of The Institution of Engineers (India): Series C, 2013
The purpose of this paper is to explain how value stream mapping (VSM) is helpful in lean implementation and to develop the road map to tackle improvement areas to bridge the gap between the existing state and the proposed state of a manufacturing firm. Through this case study, the existing stage of manufacturing is mapped with the help of VSM process symbols and the biggest improvement areas like excessive TAKT time, production, and lead time are identified. Some modifications in current state map are suggested and with these modifications future state map is prepared. Further TAKT time is calculated to set the pace of production processes. This paper compares the current state and future state of a manufacturing firm and witnessed 20 % reduction in TAKT time, 22.5 % reduction in processing time, 4.8 % reduction in lead time, 20 % improvement in production, 9 % improvement in machine utilization, 7 % improvement in man power utilization, objective improvement in workers skill level, and no change in the product and semi finished product inventory level. The findings are limited due to the focused nature of the case study. This case study shows that VSM is a powerful tool for lean implementation and allows the industry to understand and continuously improve towards lean manufacturing.
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.
Performance Improvement through Value Stream Mapping – A Manufacturing Case Study
Jurnal Kejuruteraan, 2021
The successfulness of Value Stream Mapping (VSM) as a tool for taking a snapshot of the production flow efficiency is well established. The development of a large-scale visual map of processes and their interactions is beneficial for problem analysis and subsequent solution. Through VSM, managers gain a deeper understanding of the organization processes carried out in coordination with people in a system approach. A case study was conducted at a Small and Medium Enterprise (SME) in Pakistan which manufactures ceiling fan winding machines. The aim of this study was to explore the possibilities of shortening the lead-time, waste and highlight important strategies, steps which could be undertaken by management for improvement in productivity, cost and quality. The study maps the organization systematically through the use of VSM. The Lean Implementation Techniques (LIT) steps were followed with identification of value stream process, lean metrics, mapping of current state and proposing an improved future state value stream map. The intervention suggested is layout modification by reducing 7 stations to 6 stations and streamlining the operations. The layout modification results in lower defects, controlling overproduction, managing inventory buffers from a linear approach to an optimized level. This also resulted in reduction of processing time of each unit by around 19 % and the production lead time of 100 units by around 21%. This study through VSM proposes improvement by enforcing pull system, supplier relations, modifying layout and production processes, Just in Time (JIT) delivery of materials and parts, scheduling transport resources efficiently and reducing inventory buffers.
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.
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...
Literature review using the concept of Value Stream Mapping in the manufacturing industry
Journal Industrial Servicess
Value Stream Mapping (VSM) has become a valuable tool for decision-making and identifying opportunities for lean manufacturing practices. This study reviewed literature from various sources, including Google Scholar and Science Direct, to explore the application of VSM in different sectors of the manufacturing industry. The study used specific keywords, such as "Value Stream Mapping," "Manufacturing Industry," "Waste," and "Waiting Time" to identify relevant literature. The study analyzed 42 research papers published between 2017 and 2022 to examine the development and application of VSM in the manufacturing industry. VSM has been widely adopted in various industries such as automotive, food, and textile, among others, and has been used to create action plans that combine different lean techniques to achieve optimal results. The process of VSM involves two stages, which are describing the current and future conditions. From the descriptions, areas for improvement can be identified and developed to create a lean process. Based on the reviewed literature, VSM has been found to be highly effective in the manufacturing industry.
Implementation of a Lean Model for Carrying out Value Stream Mapping in a Manufacturing Industry
Value Stream Mapping technique involves flowcharting the steps, activities, material flows, communications, and other process elements that are involved with a process or transformation. In this respect, Value stream mapping helps an organization to identify the non-value-adding elements in a targeted process and brings a product or a group of products that use the same resources through the main flows, from raw material to the arms of customers. In this study, a practical study carried out in a manufacturing industry for the manufacture of Machining center is discussed. The main aim was to draw the current state value stream mapping for the main components like Base, Column, Cross Slide, Milling Head and Table. Further, the paper has identified some of the processes which can be carried out by the sub contractor and suggested measures to be taken up by the higher level management in reducing the non value added process. It discusses the reduction in the set up time and cycle time t...