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.

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.

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.

scholarly journals Increasing Productivity by Reducing Manufacturing Lead Time through Value Stream Mapping

2012 ◽  
pp. 225-229
Author(s):  
Renu Yadav ◽  
Ashish Shastri ◽  
Mithlesh Rathore
Keyword(s):  
Lead Time ◽  
Value Added ◽  
Value Stream Mapping ◽  
Mapping Technique ◽  
Inventory Level ◽  
Lead Times ◽  
Business World ◽  
Value Stream ◽  
Current State ◽  
Future State

To survive in today’s competitive business world, companies require small lead times, low costs and high customer service levels. As such, companies pay more effort to reduce their manufacturing lead times. Value stream mapping (VSM) technique has been used on a broad scale in big companies such as Toyota and Boeing. This paper considers the implementation of value stream mapping technique in manufacturing helical springs by railway spring manufacturing company. It focuses on product family, current state map improvements and the future state map. The aim is to identify waste in the form of non value added activities & processes and then removing them to improve the performance of the company. Current state map is prepared to describe the existing position and various problem areas.. Future state map is prepared to show the proposed improvement action plans. The achievements of value stream implementation are reduction in lead time, cycle time and inventory level. It was found that even a small company can make significant improvements by adopting VSM technology. It was concluded that if we adopt the VSM technique the company could reduce the manufacturing lead time from 36.86 days to 34.06 days.

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>

Lean-Kaizen implementation

2018 ◽  
Vol 16 (1) ◽  
pp. 143-160 ◽  
Author(s):  
Sunil Kumar ◽  
Ashwani Dhingra ◽  
Bhim Singh
Keyword(s):  
Value Added ◽  
Value Stream Mapping ◽  
Inventory Level ◽  
Content Type ◽  
Value Stream ◽  
Road Map ◽  
Future State ◽  
Regular Production ◽  
Takt Time ◽  
Value Stream Map

Purpose The purpose of this paper is to present a road map to implement Lean-Kaizen concept using value stream mapping (VSM) to identify hidden continuous improvement opportunities in a small and medium-sized enterprise (SME) located at the non-capital region of India. Design/methodology/approach From the collected data, a current state map was prepared that indicated the current operating situation of selected SME. The takt time was calculated and those processes which attained higher cycle time (C/T) than takt time were identified. The continuous flow processing was achieved by adjusting C/T of each process and supermarket pull system was developed to control the production at the workstations. Finally, a future state map was developed that served as a guide for future lean activities. Few problems were identified to realize the future state. The “5-why” analysis was used for identifying root causes of these problems and Kaizen events were proposed as solutions. In this case study, one Kaizen event was identified in which brainstorming technique was used to control the variation caused by unorthodox fixture design for clamping and de-clamping of case product and thus eliminated non-value-added activities performed by the operator on a milling machine. Findings Before and after implementation of value stream map, the data obtained were analyzed and eliminated rework time, reduced inventory level, reduced lead time and C/T, improved productivity and product quality are presented as finding. Lean-Kaizen provides a better chance for every individual of the industry to have a hand in achieving organization’s goals to attain continuous progress in productivity and quality of the product. Even good understanding of the concept of lean tools and techniques by SMEs, the employee willingness and motivation to identify and eliminate wastes are found feeble. Originality/value This study is among best practices to identify hidden improvement opportunities in the regular production of the product to increase productivity and improve quality using value stream map. The research paper gives useful understandings to the lean implementers, Kaizen identifiers, consultants and researchers.

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 value stream mapping (VSM) in low-level technology organizations: a case study

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Hiluf Reda ◽  
Akshay Dvivedi
Keyword(s):  
Cycle Time ◽  
Promising Result ◽  
Product Family ◽  
Value Stream Mapping ◽  
Industrial Case Study ◽  
Content Type ◽  
Low Level ◽  
Value Stream ◽  
Time And Motion

PurposeThis research aims to improve the performance and productivity of low-level technology organizations using lean tools – value stream mapping (VSM). In order to investigate the application of VSM in low-level technology organizations, this study takes footwear manufacturing organizations as a case study.Design/methodology/approachIdentifying a suitable organization was the first step for conducting the case study, followed by product family identification. Time and motion studies are used to determine the cycle time and identify the value-adding and non-value-adding activities, respectively. After making necessary observations and calculations, the current state map was developed. Different improvement proposals were identified, and the future state map was constructed.FindingsAs a result, 56.3% cycle time reduction and 69.7% reduction in lead time were obtained, confirming its application in low-level technology organizations to improve their performance and productivity. This promising result indicates that a significant improvement can be achieved if VSM is applied in low-level organizations other than footwear industries, such as the clothing and furniture industries. Speed is investigated to be one of the parameters in motion study.Research limitations/implicationsThis study focuses on low-level technology organizations, specifically leather shoe manufacturing industries. But experiences gained from implementing this study are realistic and applicable in similar organizations.Practical implicationsPerformance and productivity improvement are critical issues to be addressed in low-level technology organizations, especially in the leather footwear manufacturing sector. This can be achieved through VSM by identifying and removing the wastes. VSM can be applied to low-level organizations as well. VSM is a powerful tool that helps managers and practitioners in identifying wastes and opportunities for improvement.Originality/valueThe paper addresses applicability of VSM in the production process of low-level technology organizations with an original industrial case study in Ethiopia.

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