scholarly journals A roadmap for improving the manifacture of automotive heat exchangers through value stream mapping

2019 ◽  
Author(s):  
◽  
Kate Lusiba
Keyword(s):  
Production Process ◽  
Heat Exchangers ◽  
Line Balancing ◽  
Value Stream Mapping ◽  
Automotive Manufacturing ◽  
Value Stream ◽  
Final Assembly ◽  
Work In Process ◽  
Value Stream Map

Lean manufacturing is an optimum approach for the reduction and elimination of waste within an organization. The case study company is based in South Africa and produces heat exchangers through main processes or fractals, which include pre-assembly, core building, brazing and final assembly. A walk through the plant showed that there was a large amount of inventory awaiting final assembly and that the brazing furnace often waited for material from core building. This was an indication that there could be an imbalance between the three fractals in terms of cycle time. Thus, the aim of this study was to improve the manufacturing processes for heat exchangers at the automotive manufacturing company through the deployment of value stream mapping, subsequent line balancing and developing a roadmap for reduction of waste. The case study research strategy was adopted for the study since it provided an in-depth view of phenomena. The first objective was to outline the production flow for the manufacture of automotive heat exchanger parts. The method used was a walk through the plant and observations were made to gain an understanding of the production steps from logistics production planning to shipping of the finished goods, and subsequently to a mapping-out of the production process flow was undertaken. The results showed that there was a large amount of inventory awaiting final assembly and that the brazing furnace often waited for material from core building. It was concluded that there was need to conduct a detailed process analysis to identify sources of waste. The second objective was to conduct value stream mapping for assessing the value- and non-value-adding activities in the manufacture of automotive heat exchangers components. A value stream map was developed through walking to Gemba and mapping out the production process, collecting data and pinpointing waste activities or areas to be improved. The kaizen flashes from the value stream map also revealed that operators were not fully utilizing the capacity of the bottleneck workstations. It was concluded that two instead of one planning points, and inefficiency at assembly were root causes of the high work-in-process level. The third objective was to conduct a line balancing analysis for the three production fractals. The method used was a Pareto analysis for evaluating the products, analysing the product mix and line balancing analysis of the production line. The results revealed that the furnace was run on two shifts while the subsequent assembly and preceding core building were running on three shifts causing a work-in-process build-up, thereby resulting in line imbalance. It was concluded that it was imperative to change the scheduling approach, and adopt one that prioritised and spread the cores that had relatively short cycle times, and also reduce downtime, change-over time as well as additional time for scrap and defects, and a future-state balance chart revealed that the fractals imbalance had been reduced. The fourth objective was to develop a roadmap for reduction of waste in the manufacture of car heat exchangers components. The method used was to develop proposals and assess the feasibility and cost implications of implementing each option. Recommendations were made for continuous process improvement and a roadmap for reduction of waste was proposed. In order to improve the output of assembly, training for the operators was recommended since it would also enable the removal of the second planning point at assembly. Further research could also be conducted to develop an optimal scheduling algorithm for allocation of products to work centres to ensure high utilization of work centres and reduce work-in-process inventory.

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 APPLY VALUE STREAM MAPPING TO “ETP ION DETECTTM” COMPANY

2020 ◽  
Vol 128 (5B) ◽  
pp. 51
Author(s):  
Hien Ton Nguyen Trong ◽  
Gareth Jones
Keyword(s):  
Material Flow ◽  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Flow Mapping ◽  
Value Stream ◽  
Work In Process ◽  
Current State ◽  
A Value ◽  
Production Value ◽  
Value Stream Map

<p><strong>Abstract: </strong>Value stream mapping (VSM) is a tool often applied in organisations working with lean in order to visualise and analyse production processes. By creating a value stream map, organisation can identify its main criticalities, look at both information &amp; material flow mapping in order to enhance lean manufacturing. Hence, the purpose of this work was to develop a value stream mapping for ETP Ion Detect Company (ETP) to demonstrate the possibilities of seeing sources of waste, shortening the lead-time, and reducing work-in-process inventory with the value stream mapping application.</p><p><strong>Key words</strong>: lean production, value stream mapping, current state map, future state map</p>

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.

Analysis Of Non Value Added Activity On Ship Production Process Approach Concept Of Value Stream Mapping Case Study At PT. Dumas Tanjung Perak Shipyard Surabaya

2017 ◽  
Vol 11 (1) ◽  
pp. 23-30
Author(s):  
An Apriyani Tebiary ◽  
I Ketut Suastika ◽  
Buana Ma'ruf
Keyword(s):  
Production Process ◽  
Value Added ◽  
Mapping Method ◽  
Value Stream Mapping ◽  
Quality Cost ◽  
Shipbuilding Industry ◽  
Value Stream ◽  
A Value ◽  
Production Effectiveness

Competition of shipyard industry market in this globalization era encourages companies to realize the importance of improving the effectiveness and efficiency so that, able to compete in terms of quality, cost and on time delivery. Production effectiveness is one effort that must be achieved by a shipbuilding industry to survive amid the competition in seizing market share. Production effectiveness is done with the aim of producing economically, continuously and on time to the customer, so that the company's survival can be guaranteed. This study aims to identify the activities that are classified as waste in the process of ship building at PT. Dumas Tanjung Perak Shipyard Surabaya so as to minimize production time in shipyard industry. The results showed the effectiveness of PT. DUMAS currently reaches 84.96%. In the process of improvement with the application of value stream mapping effectiveness value reached 92%. The conclusion of this research is a value stream mapping method can be applied measuring instrument and can describe the flow of production process in shipyard so that can explain in detail activity that give value added or non value added activity.

Analysis of Production Process in Small Business Using Value Stream Mapping Approach

2021 ◽  
Vol 65 (1) ◽  
pp. 31-35
Author(s):  
Anita Susilawati ◽  
◽  
Muhammed Sarwar ◽  
Toni Darji ◽  
Nur Iksan Agusti ◽  
...  
Keyword(s):  
Small Business ◽  
Production Process ◽  
Value Added ◽  
Value Stream Mapping ◽  
Relationship Matrix ◽  
Analysis Tool ◽  
Total Production ◽  
Value Stream ◽  
Selection Of

This paper aims to identify waste and analyse production process activities using the Value Stream Mapping (VSM) in a small business as a case study. The waste was identified by a waste relationship matrix and waste assessment questionnaire to determine the percentage of waste that occurs. Furthermore, a detailed selection of waste mapping based on the value stream analysis tool was carried out. Based on the VSM analysis, it was found the value added activities of 59% of the total production time and 41% of other activity times (non value added). In the case study occurred the waste for the operator's work method at the station of printing and cutting station. The VSM was performed to reducing the waste. The result depicted reduction in lead time on the production floor was 1.5 hours. So, the company in the case study can eliminate the waste time in their production process activities

scholarly journals Implementation of lean manufacturing to reduce waste in production line with value stream mapping approach and Kaizen in division sanding upright piano, case study in: PT. X

2018 ◽  
Vol 154 ◽  
pp. 01095 ◽  
Author(s):  
W. A. Santosa ◽  
M. Sugarindra
Keyword(s):  
Cycle Time ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Value Stream Mapping ◽  
Production Lines ◽  
Production Scale ◽  
Value Stream ◽  
Work In Process ◽  
Quality Product

PT. XY produces musical instruments such as Upright Pianos and Grand Pianos. Due to a competitive competition, a good quality product is highly required as well as increasing the production scale. To achieve these objectives, company needs to reduce wastes occurred in its production lines, particularly in the division of sanding panel upright piano (UP) which produces type of PE B1 pianos. High cycle time and lead-time are caused by wastes in UP panel sanding division. Therefore, it is needed improvements to be applied here so that the production lines will be run more effectively and efficiently. This study aims to identify wastes using Value Stream Mapping (VSM) as a tool of lean manufacturing and to implement the improvements using Kaizen. It is found that the wastes are motion and waiting. Furthermore, the improvements (kaizen) are focused on reducing motion and waiting wastes. It is shown that cycle time decreased from 51.16 minutes to 41.90 minutes, work in process or inventory can be reduced to 24 pcs over 32 pcs, and the lead-time is 0.167 days of 0.222 days.

scholarly journals Pengurangan Pemborosan Waktu Produksi Pada Proses Pembuatan Rumah Boneka Menggunakan Pendekatan Lean

Faktor Exacta ◽  
2018 ◽  
Vol 11 (3) ◽  
Author(s):  
Tiara Tiara
Keyword(s):  
Production Process ◽  
Cycle Time ◽  
Lead Time ◽  
Base Material ◽  
Line Balancing ◽  
Value Stream Mapping ◽  
Physical Factors ◽  
Production Time ◽  
Value Stream ◽  
Current State

CV. Puppet house is a small and medium-sized industrial enterprise and manufactures in producing doll house with wood base material. The purpose of this study is to know the kind of wasted production time on each production process at CV. Puppet house and give repair suggestions so as to increase the productivity of puppet house production time. This study uses a quantitative approach with the processing time of each workstation. This study uses a lean approach with tools value stream mapping (VSM), at the beginning of the study, drawing a current state mapping obtained from observations on puppets CV, then from the image was identified problem of each production process. Then analyze the problem using line balancing to level the cycle time, fishbone diagram to find out the factors causing the problem of the production of puppets and the introduction of waste on each production process. In the current state mapping the spend time of 1418.76 with 10 day lead time. After calculating and equating cycle time by using line balancing. Based on the analysis, there are several causes that can cause waste among others: delay of raw material arrival, physical factors of workers, workers who do not follow the work standards determined by the puppets and movements that are not required but performed by the workers. The proposed repair can be given to the CV of these puppets is to communicate well with the supplier, to conduct training once every 3 months to the employees, providing a special place for storage of raw materials and semi-finished materials and do not turn on television while working.<br />Keywords: Lean Manufacturing, Waste, Value Stream Mapping, Lead Time, Fshbone Diagram, CV. Rumah boneka.

Enhancement of Production Rate and Flexibility in an Assembly Line by Execution of Various Lean Techniques - A Case Study

2020 ◽  
Vol 51 ◽  
pp. 15-27
Author(s):  
D. Sobya ◽  
S. Jeyabalan
Keyword(s):  
Research Work ◽  
Value Added ◽  
Value Stream Mapping ◽  
Inventory Cost ◽  
Productivity Improvement ◽  
Value Stream ◽  
Work In Process ◽  
Assembly Area ◽  
Valve Assembly

This research work mainly focuses on the flexibility and productivity improvement through the execution of different lean techniques in the valve assembly of medium scale manufacturing unit. The different types of wastes percentage are determined to find out the waste which mainly affects the productivity. The major wastes of motion waste by about 30% and unwanted distance of 250 square foot were reduced by implementation of kaizen in the valve assembly area. Value stream mapping was used to identify the bottleneck process and by eliminating the bottleneck process results in the reduction of excess motion and non-value added activity by 45%. Work-in-process aging and work-in-process inventory cost was calculated and the production level was estimated by using 95th Percentile calculation. The total lead time was reduced about 54minutes with reduction of transportation time 2.7minutes after the implementation of lean techniques and the productivity of the valve assembly was also increased to about 6% after reducing the non-value added activities.

Sign in / Sign up

Export Citation Format

Share Document