Application of lean in construction using value stream mapping

2019 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Prasanna Venkatesan Ramani ◽  
Laxmana Kumara Lingan KSD
Keyword(s):  
Construction Projects ◽  
Manufacturing Industry ◽  
Value Stream Mapping ◽  
Content Type ◽  
Project Duration ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Increase In Productivity

Purpose Lean construction is a technique that aims at reducing waste in construction and maximizing productivity. The purpose of this paper is to discuss the effectiveness of Lean technique in managing construction projects. Design/methodology/approach A case study of structural steel erection project was chosen where the value stream mapping lean tool is applied and the possible improvement in productivity was observed. The current state of the activities in the erection process was mapped first which was followed by preparing the Future State Map of the activities after eliminating the non-value adding tasks. Findings The modifications from Future State Map were carried out at the project and the results exhibited a substantial increase in productivity by reducing the project duration by 13 days which is about 30 per cent savings from the expected completion time after the implementation of Lean technique. Originality/value Traditionally lean concept has been widely used in process-oriented manufacturing industry whereas it is relatively new to the project-oriented construction industry. This current research has focused on applying lean tool to a real time construction project at the site level and measuring its outcome practically. The results of this study are real and affirm the effectiveness of applying lean concept to construction projects. It will be major paradigm shift in terms of managing construction projects.

An application of value stream mapping in auto-ancillary industry: a case study

2019 ◽  
Vol 32 (1) ◽  
pp. 162-182 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Srinivas Kota ◽  
Kuldip Singh Sangwan
Keyword(s):  
Product Family ◽  
Value Stream Mapping ◽  
Inventory Level ◽  
Specific Product ◽  
Content Type ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Auto Component

Purpose Lean manufacturing (LM) plays a major role in eliminating wastes (activities/resources) in a manufacturing organization. Value stream mapping (VSM) is one of the critical tools in LM which will help in identifying wastes in materials and information flow in a specific product family. The purpose of this paper is to illustrate the significance of VSM in the auto-ancillary industry in enhancing the productivity and the quality. Design/methodology/approach A case study approach is followed to demonstrate the significance of VSM in identifying various wastes in the auto-ancillary industry. The study has been performed by implementing seven critical steps. A product family is identified based on the customer demand and a cross functional team with specialized experts was formed. The overall processes with sequence are mapped using process flowchart. A cross functional team has been formed to develop the current state of VSM and perform a critical analysis to identify shortcomings. An investigation was performed to overcome the existing shortcomings by identifying opportunities. The relevant kaizens to improve the current state have been proposed. The cross functional team of experts have performed a feasibility study on implementation of proposed kaizens. Finally, a future state of VSM after implementation of feasible kaizens has been reported. Findings The results show that future state of VSM brings out the positive impact with respect to process ratio, TAKT time, process inventory level, total lead time and bottleneck time. The proposed improvement also helped to achieve higher customer satisfaction in terms of increased quality, reduced cost and on time delivery. Research limitations/implications Present study is focussed on a single product family cell in one of the auto-component organization. Originality/value Helps practitioners in the auto-component industry to implement the VSM effectively in their organization.

Development of sustainable value stream mapping (SVSM) for unit part manufacturing

2019 ◽  
Vol 11 (3) ◽  
pp. 493-514 ◽  
Author(s):  
Aatish Kumar Mishra ◽  
Ayush Sharma ◽  
Moraldeepsingh Sachdeo ◽  
Jayakrishna K.
Keyword(s):  
Manufacturing Industry ◽  
Main Tool ◽  
Organizational Level ◽  
Value Stream Mapping ◽  
Simulation Approach ◽  
Content Type ◽  
Study Approach ◽  
Value Stream ◽  
Sustainable Value

Purpose The main purpose of this paper is to analyze the current state of a bonnet-manufacturing industry and to optimize the process by designing a future state map using simulation approach. Design/methodology/approach The case study approach has been proposed to highlight the applicability of value stream mapping (VSM) in an Indian bonnet manufacturing organization. The methodology used relies on formulation of VSM being the main tool used to identify the opportunities for classifying and eliminating bottlenecks with the help of various lean techniques. A contrast of present and past scenarios is highlighted to underscore the importance of using VSM with ARENA simulation. Findings Application of the proposed simulation approach has helped the organization reduce the cycle time significantly by 30 per cent over the entire production time. The average number of work-in-progress pieces has also decreased by about ten. In addition, enhancements have been seen with respect to ecological parameters, e.g. carbon footprint has been reduced to 83.7 percent across the process. Research limitations/implications The proposed approach of using a simulation-based VSM helps in reducing the time involved in traditional VSM method. This approach is also easy to implement at any organizational level. Practical implications It is believed that this paper will aid not just industrialists but also academic professionals to appreciate the role of simulation using ARENA in helping them understand how to attack the various problems faced by industries. The results of the study indicate that by applying this methodology, there will be a reduction not only in cost but also in environmental impacts. Originality/value The paper incorporates a real case study, which shows application of VSM for implementing lean principles in a bonnet-manufacturing industry. Break-even analysis presented fills the gap which previous literatures have been missing.

Managing industrial operations by lean thinking using value stream mapping and six sigma in manufacturing unit

2019 ◽  
Vol 58 (6) ◽  
pp. 1118-1148 ◽  
Author(s):  
Jagdeep Singh ◽  
Harwinder Singh ◽  
Amandeep Singh ◽  
Jashanpreet Singh
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Manufacturing Industry ◽  
Value Stream Mapping ◽  
Lean Thinking ◽  
Content Type ◽  
Value Stream ◽  
Future State ◽  
Industrial Operations

Purpose The purpose of this paper is to cover the significance of lean thinking using value stream mapping and six sigma methodology in managing industrial operations. Design/methodology/approach Lean manufacturing is an efficient approach for identifying and eliminating waste through a continuous improvement via flow of the product/service at the pull of customer in chase of exactness. This study has been carried out in a manufacturing unit of Northern India that was suffering from high production lead time and work in progress (WIP) inventory. Findings The current state and future state maps for the critical product have been prepared. On comparison of both current and future state maps, it was observed that lead time has been reduced by 14.88 percent, processing time by 14.71 percent and wastage of material movement by 37.97 percent. As proposed in model, the WIP inventories have been reduced by 17.76 percent and workforce by 17.64 percent. Further it would lead to the profit of Rs161,800 per annum. Six sigma projects have been carried out to reduce rejections of the critical product P-19 under study. The total length of the product was undersize of the critical product. Root cause analysis technique has been used through strategic DMAIC implementation. Results of investigation demonstrated net savings of rupees 145,560 annually. Originality/value The paper demonstrates the practical application of lean thinking, showing how it can bring real breakthroughs in saving cost in the manufacturing industry.

Lean manufacturing implementation using value stream mapping as a tool

2014 ◽  
Vol 5 (1) ◽  
pp. 89-116 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Aditya Sharma
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Process Time ◽  
Inventory Level ◽  
Specific Product ◽  
Content Type ◽  
Value Stream ◽  
Work In Process ◽  
Current State

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.

scholarly journals Application of value stream mapping to enhance productivity by reducing manufacturing lead time in a manufacturing company: A case study

2021 ◽  
Vol 19 (1) ◽  
pp. 11-22
Author(s):  
Aditya S. Patil ◽  
Mahesh V. Pisal ◽  
Chandrakant T. Suryavanshi
Keyword(s):  
Lead Time ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Lead Time Reduction ◽  
Current State ◽  
Future State ◽  
Short Lead Time ◽  
Time Gap ◽  
Value Stream Map

Lead time is a time gap between initiation and completion of the processes or product. The lead time directly affects productivity. Short lead time results in higher output thus add more value in a given period. Value stream map is an effective tool to describe the overall process from order to delivery. In this study, there is lead time reduction by generation current state and future state for a process using various techniques. Thus, the main aim of this work to enhance production by reduction of lead time. Finally, gain in production, reduction in lead time, and reduction in inventory between the stations are also reported.

Lean service system design: a simulation-based VSM case study

2019 ◽  
Vol 25 (7) ◽  
pp. 1802-1821 ◽  
Author(s):  
Fatih Cavdur ◽  
Betul Yagmahan ◽  
Ece Oguzcan ◽  
Nazli Arslan ◽  
Nurbanu Sahan
Keyword(s):  
Design Methodology ◽  
Simulation Models ◽  
Public University ◽  
Decision Makers ◽  
Value Stream Mapping ◽  
Content Type ◽  
Value Stream ◽  
Future State ◽  
Simulation Based

Purpose The purpose of this paper is to present a methodology for using simulation models together with value stream mapping (VSM) for designing lean service systems and illustrate it with a case study. Design/methodology/approach The authors propose a methodology combining simulation and VSM. Simulation models for both current and future states are developed to validate the results of the corresponding maps of current and future states, respectively. Findings The results illustrate the advantages of the suggested design represented by the future state map. Additionally, using simulation models together with VSM for validating current and future states also allows decision makers to perform comprehensive analyses on the system and draw statistical conclusions. Originality/value Although some lean applications in educational services exist in previous studies, according to the best of the authors’ knowledge, this study is the first one combining VSM and simulation for the implementation of the lean concepts in the construction and technical services of a public university.

scholarly journals APLICAÇÃO DO MAPEAMENTO DE FLUXO DE VALOR EM UMA INDÚSTRIA DE COMPONENTES PARA CALÇADOS DO VALE DO SINOS

2019 ◽  
Vol 10 (2) ◽  
pp. 137
Author(s):  
Eduardo Herzer
Keyword(s):  
De Novo ◽  
Value Stream Mapping ◽  
Ongoing Activity ◽  
Lean Thinking ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
The Future ◽  
Is Value

Reduzir custos e desperdícios é uma atividade continua dentro da empresa para que elas se perpetuem. Para facilitar esta atividade, pode ser utilizado ferramentas e métodos para verificar o que realmente pode ser efetuado e em que ponto do processo e das operações. Uma ferramenta é o Mapeamento do Fluxo de Valor, que tem como objetivo desenhar o estado atual e desenhar o estado futuro com a finalidade de melhorar os pontos levantados por meio de aplicação de princípios da mentalidade enxuta. Este artigo aborda a aplicação desta ferramenta em uma indústria de Componentes de Calçados de Novo Hamburgo (RS) e traz como resultados a as sugestões de aplicação de ferramentas de produção enxuta. A pesquisa ocorreu no ano de 2015, onde por meio de um estudo de caso e exploratório foi possível construir os mapas e propor melhorias por meio de um estudo de caso. Os resultados apontam a existência de desperdícios em diversos pontos do fluxo de valor avaliado e o mapa de estado futuro sugere a aplicação de ferramentas para reduzir os desperdícios identificados.Palavras-chave: Lean Thinking. Mapeamento de Fluxo de Valor. Componentes para Calçados.ABSTRACTReducing costs and waste is an ongoing activity within the company to perpetuate it. To facilitate this activity, tools and methods can be used to verify what can actually be done and at what point in the process and operations. One tool is Value Stream Mapping, which aims to draw the current state and draw the future state in order to improve the points raised through the application of lean mindset principles. This article discusses the application of this tool in a footwear components industry in Novo Hamburgo (RS) and brings as a result the suggestions for applying lean production tools. The research took place in 2015, where through a case study and exploratory it was possible to build the maps and propose improvements through a case study. The results indicate the existence of waste in several points of the evaluated value stream and the future state map suggests the application of tools to reduce the identified waste.Keywords: Lean Thinking. Value Stream Mapping. Components for Shoes.

scholarly journals Green productivity: waste reduction with green value stream mapping. A case study of leather production

2021 ◽  
Vol 9 (1) ◽  
pp. 47
Author(s):  
J. Prayugo ◽  
L.X. Zhong
Keyword(s):  
Production Line ◽  
Waste Reduction ◽  
Value Stream Mapping ◽  
Analysis Model ◽  
Green Waste ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Green Productivity

<p>This study aims to identify and reduce waste in PT Rajapaksi Adya Perkasa manufacturing company. The analysis uses the concept of green productivity with Green Value Stream Mapping as the analysis model. Through the GVSM current state, this study calculates the amount of green waste in the production line including seven green waste. The result of this study shows an improvement to minimize the waste that occurs through the GVSM future state. GVSM technique increases the green productivity value from 1.12 to 1.81.</p>

Achieving Lean Warehousing Through Value Stream Mapping

2020 ◽  
Vol 9 (3) ◽  
pp. 387-401
Author(s):  
Abhishek P.G. ◽  
Maheshwar Pratap
Keyword(s):  
Lead Time ◽  
Value Stream Mapping ◽  
Lead Times ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Lean Tools ◽  
Warehouse Operations ◽  
High Lead

This article applies value stream mapping (VSM) in a distribution warehouse after identifying and categorizing different warehousing wastes. The study suggests solutions for the reduction of each type of waste and employs lead time as the metric to understand the overall effectiveness of the suggested remedies. The distribution warehouse faced severe stock-out situations and high lead time for all deliveries. Current state and future state maps were utilized for mapping the current and revamped system, respectively. While existing studies on lean warehousing have utilized VSM to study a specific type of waste, this study extends it to include all types of warehousing waste, classifies them into seven types and provides a real case study along with evidence for improvement schemes for each category. This research, employing a case study, suggests an integrated lean warehousing method for design and operation of distribution warehouses. Dilemma/research question/purpose: Can the warehouse avoid stock-outs and decrease the lead time by identifying and reducing or eliminating the seven types of wastes in the warehouse operations? Theory: Lean management principle applied to a warehouse using value stream mapping to eliminate wastes. Type of the case: A problem-solving using lean tools carried out in a warehouse. Protagonist: Not needed. Options: Allow the current state to continue causing stock-outs and high lead times, or identify and reduce the wastes in the warehouse operations and avoid stock-outs, decrease lead times, and improve the overall efficiency of the warehouse. Discussions and case questions: Is it possible for the firm to go one step further than what the future state map has shown in the study? What other lean tools do you see fit to reduce or eliminate the types of waste outlined in this article?

Application of lean manufacturing in automotive manufacturing unit

2020 ◽  
Vol 11 (1) ◽  
pp. 171-210 ◽  
Author(s):  
Jagmeet Singh ◽  
Harwinder Singh
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Value Added ◽  
Value Stream Mapping ◽  
Automotive Manufacturing ◽  
Content Type ◽  
Work In Process ◽  
Current State ◽  
Future State ◽  
Manufacturing Organization

Purpose This paper aims to apply lean manufacturing using value stream mapping (VSM) in the manufacturing organization (automotive suspension and fastening components section). To validate the VSM approach, simulation has been done. Design/methodology/approach VSM approach has been used to implement lean stages in the U-bolt section. Current state map was prepared and future state map has been implemented. Further, simulation has been done to compare current state and future state maps. Findings It has been found that there is 87.59% reduction in cycle time (C/T), 76.47% reduction in work-in-process (WIP) inventory, 95.41% reduction in production lead time, 66.08% increase in value added (VA) ratio, 95.78% reduction in non-value added (NVA) time, 57.14% reduction in the number of operators and 70.67% reduction in change over (C/O) time for the U-bolt section. Simulated and VSM of current and future state has observed error of 5 s. Research limitations/implications This study is based on automotive manufacturing industry situated in northern part of India. The outcome of this study is applicable only to the selected product of the manufacturing company. Originality/value This paper deals with case study part which reflects the true picture of implementation of Lean manufacturing (LM) tools in the organization.

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