Lean manufacturing implementation using value stream mapping as a tool

Abstract

Purpose – Value stream mapping (VSM) is a lean manufacturing (LM) tool used for analyzing material and information flow on a specific product family. The purpose of this article is to address the importance of VSM in LM environment in an Indian auto components industry. Design/methodology/approach – The case study approach has been used to show the applicability and importance of VSM in an Indian auto components company, in which the current state of manufacturing is mapped with the help of VSM symbols. According to the current state mapping, the study conducted analysis and identifies the area of improvement needed in terms of work in process, lead time and cycle time. The study further implemented kaizen on the current state map and developed future state map while including these kaizens. Findings – The study clearly shows that the VSM brings out the positive impact on process ratio, TAKT time, process inventory level, line speed, total lead and process time and reduced man power. It is helping the company in satisfying their customers with respect to quality, cost and delivery. Research limitations/implications – The main limitation of the study is the confined focus on a single industry. The case should be extended to other industries in order to support the findings and for the purpose of the wider generalization. Practical implications – The results obtained from the study will help other industries and sectors to implement VSM in LM environment. Originality/value – The article deals with a real case study, which shows application of VSM for implementing lean principles.

Análise Da Correlação Do Lean Manufacturing Com Produtos Modulares

“…A busca do layout mais eficiente também ocorre no Lean Manufacturing, devido a busca de reduzir tempos não produtivos, como os tempos de movimentação das peças na linha de produção. (Carmignani, & Zammori, 2015 p. 994;Lopes, Freitas, & Sousa, 2015;Jasti, & Sharma, 2014). O mapeamento do fluxo de valor para reduzir atividades não produtivas é um dos destaques da produção Lean Manufacturing; a. Melhoria da qualidade (Chaplin, & O'rourke, 2016).…”

“…Análise do Fluxo de valor (Carmignani, & Zammori, 2015 p. 994); SMED (Lopes et al, 2015). O mapeamento de valor (Jasti, & Sharma, 2014).…”

“…O mapeamento de valor e o kaizen melhoram o processo de fabricação, (Jasti, & Sharma, 2014). O mapeamento de valor e o kaizen reduziu os estoques, (Jasti, & Sharma, 2014).…”

A Research on Implementation of Lean Tools Across Verticals in Manufacturing

“…Aditya Sharma [4] checked the application of VSM in Indian auto component Industry and proved it to be much beneficial since it helped to identify all types of lean waste and improvement areas where other tools for improvements. Also it was found that top management involvement is one of the important factors for successful lean implementation.…”

14th Annual International Bata Conference

“…Singh, Garg, & Sharma, 2009) and automotive manufacturing (Lacerda, Xambre, & Alvelos, 2016;H. Singh & Singh, 2013;Vamsi Krishna Jasti & Sharma, 2014). Others have focused on less common areas such as product development (Peek & Chen, 2011;Tyagi, Choudhary, Cai, & Yang, 2015), architecture (Lima, Rolim, & Alves, Thais da C L, 2010), construction (Matt, Krause, & Rauch, 2013), call centre (Piercy & Rich, 2009), transport (Villareal, Garza, Rosas, & Garcia, 2012) and maintenance service (Kasava, Yusof, Khademi, & Saman, 2015).…”