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Value Stream Mapping: A Case Study of Automotive Industry

2014, International Journal of Research in Engineering and Technology

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IOSR Journals

The A value stream includes all activities required to transform a product from raw material into the finished goods. Value Stream Mapping scrutinizes business processes from beginning to end and a visual representation map is drawn of every process involved in the material and information flows. Then a future state map is drawn to show how things should work for best competitive advantage. Value Stream Mapping helps to identify the current flow of material and information in processes for a family of products, highlighting the opportunities for improvement that will most significantly impact the overall production system. Nowadays in a competitive market, companies require small lead time, low costs and high customer service levels. As such companies pay more effort to reduce lead time. Value Stream Mapping (VSM) is the one of the lean manufacturing tool. In this study we will utilize value stream mapping (VSM) technique to identify and eliminate different types of wastes in fastener industry. The current state is mapped to capture a snapshot of how things are done and where the improvement potentials lie. Future state map is made to show the implementation action plan considering takt time. A case study carried out in Morning Star Industries Ludhiana, India.

IOSR Journals publish within 3 days

Bus body manufacturing play a key role in automotive manufacturing, as vehicle manufacturers often sub contract such enterprise to complete bus manufacturing process. In a fiercely competitive global environment, the bus body manufacturing enterprises are constantly looking for ways of meet their customer requirements of delivery on time, cost and quality in order for them to survive. However, bus body manufacturing enterprises barely meet the customer demands in terms of delivering on time due to long cycle times on the production floor due to low labour utilization, material wastage and unorganized work flows. In this research, we critically looked at improving productivity such enterprises by considering a case study of one of the leading bus body manufacturing enterprises in Kenya. Value Stream Mapping was used as the main productivity improvement tool supported by line balancing techniques. The results from the improved value stream map indicated an increase in efficiency of 13.1% and a reduction the cycle time by 7 days, demonstrating the potential of these tools for improving productivity in bus body manufacturing.

ICSESD-2017

Pranav Charkha

International Journal of Scientific Research in Science and Technology IJSRST

Today, Lean manufacturing Tools and Techniques are widely used for eliminating various kinds of waste and increase profit of organization by making process more efficient. Lean is about doing additional with less: Less time, inventory, space, people, and money. Lean is about speed and obtaining it right the first time. The Lean manufacturing approach is meant to transform non-value added activity into value added activity. Lean manufacturing has its impact on the employees and also the customers alike. A lean organization understands customer value and focuses its key processes to continuously increase it. The ultimate goal is to produce perfect value to the customer through an ideal value creation methodology that has zero waste. This paper provides the literature survey on lean tools and lean implementation technique of implementing lean manufacturing.

Duong Huong

In Bangladesh a significant amount of foreign currency comes from the RMG sector. Garment industries in developing countries are more focused on sourcing of raw material and minimizing delivery cost than labor productivity because of the availability of cheap labor. Due to this, labor productivity is lower in developing countries than in the developed ones. So productivity improvement is one of the major concern in garments factories. This paper addresses the scope of value stream mapping (VSM) application in a selected garments factory of Bangladesh. The core idea behind the thesis work was to examine the existing condition of production system where there is no application of VSM technique and to analyze the scope of VSM technique application in the studied production line. The main objective of the research paper is to identify various wastes occurs in the production system. Additionally it tries to find out some areas for improvement and propose some improvement strategies. In this concern this case study has been conducted focusing cutting, finishing and on a particular production line of sewing section in a selected garments factory. During the investigation, attention has been concentrated how non-value adding activity hampers daily production rate and how to improve the productivity. Value adding, non-value adding (necessary and unnecessary) processes and different types of wastes have been identified by drawing the current state map for cutting, sewing and finishing sections. The study focuses on removing the big losses namely, breakdown losses, quality loss, small stops, startup rejects to improve the effectiveness of the production line. Some strategies are proposed for reducing these losses and improving the overall productivity. It is found that the non-value adding time has contributed significantly in total production lead time. Finally, a future state map has been proposed to the management that will be benefited for productivity improvement of the existing production system as well as to reduce the non-value adding time. 1. Introduction In Bangladesh, the Ready Made Garment (RMG) Industry has emerged as a major economic sector and has had its impact on the financial service sector, communication, transportation and on other related industries. 2 million workers in 4,000 factories, which is about one-fourth of the number of employees engaged in the manufacturing sector, constitute the real backbone of the country's economy [1]. Garment industries in developing countries are more focused on sourcing of raw material and minimizing delivery cost than labor productivity because of the availability of cheap labor. Due to this, labor productivity is lower in developing countries than in the developed ones. For example, labor is very cheap in Bangladesh but the productivity is low among other developing countries. Similarly, the cost of fabric is a major part of the garment so there seems to be great need for improvement in this sector. Even in developing countries the CAD and CAM system for fabric cutting has been implemented to save fabric. Now the worry is about labor productivity and making production flexible. The fashion industry is highly volatile and if the orders are not fulfilled on time, the fear for losing business is real. This means that time is very important driver for success. The Company that delivers goods with a shorter lead time is the market winner. This can be achieved greatly by adopting lean manufacturing system which is more than a cost reduction program. It aims at eliminating wastes which could be in the form of excess production and inventory, redundant movement of material, waiting and delays, over processing, excess worker motion, rework and corrections. Part of lean manufacturing is assessing operations and processes or products that add cost rather than value. Each step of the manufacturing process is examined to determine if it adds value to the product. If it does not add value, the process could be assigned to a subcontractor or outsourcing company in order to focus the workforce on value-added operations of its core business. This is known as value stream which is a set of processes required to transform raw materials into finished goods that customer's value. In this research work, the scope of one of the most important Lean Manufacturing tool called " Value Stream Mapping " will be evaluated in a selected garments factory

IAEME PUBLICATION

IAEME Publication

Purpose: The purpose of this paper is to implement lean to determine and eliminate various wastes with the help of Value Stream Mapping. It aims at representing a Current and Future State Maps to give overview of improved areas in waste and resource management in Indian Manufacturing Firm. By the detailed study processes involved in industry, the existing stages have been mapped with the help of Value Stream Mapping. After which improvement related areas are identified like cycle time, production lead time etc. Considering the current processes of the industries operations Current State map is developed to show how actual production is taking place at the industry before implementing any lean procedure. A Future State Map is finally developed considering the lean behavior to reduce the waste production and to increase its productivity. After a thorough comparison between Current and Future State Map of the Indian Manufacturing Firm a 78.8% decrease production lead time was investigated, followed by 28.4% reduction in cycle time. Also a significant decrease in WIP and manpower requirements was observed. This case study presents VSM as a robust tool for implementing lean and to give proper insight to industry managers and researchers to know techniques of improving lean implementation.

International Journal of Engineering Research and General Science

Chowdhury Rahman , Mostafizur Rahman Sobuj

In Bangladesh a significant amount of foreign currency comes from the RMG sector. Garment industries in developing countries are more focused on sourcing of raw material and minimizing delivery cost than labor productivity because of the availability of cheap labor. Due to this, labor productivity is lower in developing countries than in the developed ones. So productivity improvement is one of the major concern in garments factories. This paper addresses the scope of value stream mapping (VSM) application in a selected garments factory of Bangladesh. The core idea behind the thesis work was to examine the existing condition of production system where there is no application of VSM technique and to analyze the scope of VSM technique application in the studied production line. The main objective of the research paper is to identify various wastes occurs in the production system. Additionally it tries to find out some areas for improvement and propose some improvement strategies. In this concern this case study has been conducted focusing cutting, finishing and on a particular production line of sewing section in a selected garments factory. During the investigation, attention has been concentrated how non- value adding activity hampers daily production rate and how to improve the productivity. Value adding, non-value adding (necessary and unnecessary) processes and different types of wastes have been identified by drawing the current state map for cutting, sewing and finishing sections. The study focuses on removing the big losses namely, breakdown losses, quality loss, small stops, startup rejects to improve the effectiveness of the production line. Some strategies are proposed for reducing these losses and improving the overall productivity. It is found that the non-value adding time has contributed significantly in total production lead time. Finally, a future state map has been proposed to the management that will be benefited for productivity improvement of the existing production system as well as to reduce the non-value adding time.

International Journal of Productivity and Quality Management

Rajarajanramji Mohanraj

International Journal of Latest Technology in Engineering, Management & Applied Science -IJLTEMAS (www.ijltemas.in)

For any Company's economy, the industry cost, production time, total quality management and waste reduction have great impact. The investments consumed by the company by eradicating non value added production work and time are very important. Focusing on these points Lean Manufacturing tools, a Japanese strategy, is implemented in this work. An apparel industry was studied and the bottleneck areas were identified through Value Stream Mapping (VSM). The bottleneck areas were identified and eliminated by implementing line balancing and parallel working section. The implementation of kaizen resulted in reduction of cycle time by 48.7%.

International Journal of Engineering Research and Technology (IJERT)

IJERT Journal

https://www.ijert.org/lead-time-reduction-in-windmill-control-panel-manufacturing https://www.ijert.org/research/lead-time-reduction-in-windmill-control-panel-manufacturing-IJERTCONV7IS06072.pdf The prime purpose is to reduce the lead time of windmill control panel manufacturing by implementing lean manufacturing by the use of lean tools to achieve the takt time in electrical control panel assembly line. The ''lean'' approach has been applied more frequently in automobile assembly and machine tool building then in electrical control panel manufacturing company. The lean system was developed with reduced non value added activities so that greatly reduces the seven Mudas. People work with a greater confidence, with greater ease, and with greater peace than the typical manufacturing facility. Value stream mapping and line balancing was the main tool used to identify the opportunities for various lean techniques. We described a simulation model that was developed to contrast the ''current'' and ''Future'' scenarios in detail, in order to illustrate the potential benefits such as reduced production lead-time and lower work-in-process inventory. Work instructions is displayed in all the assembly stations also improved the performance of the line workers.

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Value stream mapping and lean simulation: a case study in automotive company

• ORIGINAL ARTICLE
• Published: 19 October 2015
• Volume 85 , pages 547–555, ( 2016 )

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• P. F. Andrade 1 ,
• V. G. Pereira 1 &
• E. G. Del Conte 1  

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This work aims at applying the concepts of value stream mapping (VSM) in an auto-parts company in the ABC region of Sao Paulo. By mapping the current state of art, it was possible to identify the waste present in an assembly line of clutch discs. The future state was suggested with improvements for elimination of waste and reduction of lead time, which went from 60.5 to 4.14 days. Simulations were made using current and future states to support the suggested improvements, and reduction of 7 % in total production time was verified, as well as 10 % increase in the use of work positions. The results showed that VSM combined with simulation is a good alternative in the decision-making for change in production process.

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Andrade, P.F., Pereira, V.G. & Del Conte, E.G. Value stream mapping and lean simulation: a case study in automotive company. Int J Adv Manuf Technol 85 , 547–555 (2016). https://doi.org/10.1007/s00170-015-7972-7

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Received : 11 July 2015

Accepted : 12 October 2015

Published : 19 October 2015

Issue Date : July 2016

DOI : https://doi.org/10.1007/s00170-015-7972-7

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Value Stream Mapping (VSM) is a useful tool to see hidden wastes and sources of these wastes in a manufacturing facility, primarily for discerning between activities that adds value to the process and activities that do not. It is one of the key lean tools used to identify opportunities for eliminating non-value adding activities, reducing production lead time and lowering work-in-process (WIP) inventory. This paper demonstrates a case study of VSM application at a special purpose lock manufacturing facility. A current state map is drawn to document how processes are operated on production floor. Through aggressive application of process improvement techniques, a future state map is developed to design a lean process flow by eliminating wasteful activities. In a major overhaul of activities, the existing process layout riddled with excessive inter-station travels was changed to an effective and cost efficient product layout. In addition, lean tools like 3G, Kaizen and 5S were implemented for better utilization of manufacturing facilities. The outcome was seen in the drastic reduction achieved in production lead time and WIP inventory. Production lead time and WIP inventory decreased by 62.74% and 66.09% respectively. Furthermore, rejection levels and unwanted travels were drastically reduced.

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