Evaluating lean thinking using value stream mapping in manufacturing industry - a case study

2017 ◽  
Vol 22 (1) ◽  
pp. 101
Author(s):  
Kultaran Singh ◽  
Jagdeep Singh ◽  
Harwinder Singh ◽  
Deepinder Singh
Keyword(s):  
Manufacturing Industry ◽  
Value Stream Mapping ◽  
Lean Thinking ◽  
Value Stream

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.

scholarly journals Lean thinking to improving access to cancer patients in a Public General Hospital

2015 ◽  
Vol 1 (1) ◽  
pp. 1-8
Author(s):  
Carlos Frederico Pinto ◽  
Stela Maris Coelho ◽  
Evelin Araujo Marotta ◽  
Sheila Vianna Reis ◽  
Robisom Damasceno Calado ◽  
...  
Keyword(s):  
Value Stream Mapping ◽  
Lean Thinking ◽  
Process Redesign ◽  
Cancer Centers ◽  
Value Stream ◽  
Unit Capacity ◽  
Case Study Report ◽  
Lean Methods ◽  
Unit Performance

Unbalanced treatment scheduling and overcrowding is a common problem for cancer centers in Brazil, with huge access restrictions due to system inefficiencies and poor assistance design. The purpose of this report is to show how lean thinking can be applied to healthcare by using lean methods and production leveling. The case study / report presented was adopted in order to describe the approach, techniques and findings of this project, as part of a lean initiative. Lean Value Stream Mapping tools and leveling tools improved unit performance by increasing unit capacity freeing treatment slots by leveling and decrease of waiting time for cancer treatment .The process redesign also eliminated unnecessary movement and overtime.

Implementation of Lean Tools in an Automotive Industry for Productivity Enhancement - A Case Study

2017 ◽  
Vol 29 ◽  
pp. 175-185 ◽  
Author(s):  
S. Nallusamy ◽  
M.A. Adil Ahamed
Keyword(s):  
Automotive Industry ◽  
Manufacturing Industry ◽  
Value Added ◽  
Value Stream Mapping ◽  
Lean Principles ◽  
Value Stream ◽  
Whole Process ◽  
Lean Tools ◽  
Cycle Efficiency

Value stream mapping has the reputation of uncovering waste in manufacturing, production and business process. This helps in identifying and removing or streaming value added steps and eliminating non value added steps. In this study the process was analyzed to find an opportunity to drastically reduce the number of actions and to simplify the same. By reducing waste the proportion of value adding time increases in the whole process and the process throughput speed could also be increased. This makes the redesigned process more effective and more efficient. The reengineered process was flow charted in its future state with process steps and information flows re-engineering, simplified and economized. The current layout was analysed to identify and eliminate the non value added activities through lean tools like 5S, VSM and line balancing in a manufacturing industry. From the observed results, it was concluded that the non value added time could be reduced by about 13% while the process cycle efficiency could be increased by about 10%. Virtual simulation was conducted to verify and validate the existing situation as well as to propose the results and the effectiveness of lean principles in a systematic manner with the help of ARENA.

scholarly journals Lean Manufacturing Applications in the Manufacturing Industry

2018 ◽  
Vol 220 ◽  
pp. 02005
Author(s):  
Abdillah Arif Nasution ◽  
Ikhsan Siregar ◽  
Anizar ◽  
Tigor Hamonangan Nasution ◽  
Khalida Syahputri ◽  
...  
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Value Added ◽  
Added Value ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Mapping Analysis ◽  
Manufacturing Applications ◽  
Study Application

This research was conducted in manufacturing industry, so this research is based on case study application. This research serves to reduce waste in the industry when making a product. This study categorizes value-added work and which work has no added value. And it is measurable and has value, so it can be evaluated in the future. Later this will be poured or depicted on a map called Value stream mapping. This is a tool from Lean Manufacturing. Lean manufacturing is useful for analysing and reducing non value-added activities, value stream mapping analysis tools, 5L1H process mapping activities, and 5 why tools. From the results of this study obtained the efficiency of the process cycle and total estimation of the improvement of the lead time. This calculation can be an evaluation material for the company.

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.

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.

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