Evaluation of the production flow of a Nigerian medium scale manufacturing company using value stream mapping

2018 ◽  
Vol 12 (4) ◽  
pp. 385
Author(s):  
T.E. Abioye ◽  
O.O. Awopetu ◽  
S.A. Ojebode
Keyword(s):  
Value Stream Mapping ◽  
Production Flow ◽  
Medium Scale ◽  
Value Stream ◽  
Manufacturing Company

Efficiency Enhancement in a Medium Scale Gearbox Manufacturing Company through Different Lean Tools - A Case Study

2018 ◽  
Vol 34 ◽  
pp. 128-138 ◽  
Author(s):  
V. Saravanan ◽  
S. Nallusamy ◽  
Abraham George
Keyword(s):  
Lean Manufacturing ◽  
Processing Time ◽  
Assembly Line ◽  
Value Added ◽  
Value Stream Mapping ◽  
Productivity Improvement ◽  
Medium Scale ◽  
Value Stream ◽  
Manufacturing Company

Productivity is an important parameter for all small and medium scale manufacturing industries. Lean manufacturing emerged as production strategy capable of increasing productivity by identifying and eliminating non value added activities. This article deals with productivity improvement in a pre-assembly line of gearbox manufacturing company with a case study using lean concepts like process flow chart, process Gantt chart and time study. This paper illustrates using a case study on how a value stream mapping has to be carried out in a planet carrier pre-assembly line. Value stream mapping and work standardization are the key tools used in lean manufacturing and lean transformation. It makes the process smoother, helps in reduction of lead time and ultimately increasing the productivity. From the observed results it was found that, the productivity has been increased from 7 pieces to 10 pieces in the first step assembly when the proposed VSM was implemented. The second step processing time was reduced by the execution of proposed value stream mapping with TAKT time of 126 minutes and 165 minutes of processing time for demand of 10 pieces were achieved and the overall processing time has been reduced by about 24%.

Production Improvement in an Aircraft Manufacturing Company Using Value Stream Mapping Approach

2014 ◽  
Vol 660 ◽  
pp. 1038-1042 ◽  
Author(s):  
Md Saidin Wahab ◽  
Kamsidi Abd Malek Sidek ◽  
Mohd Shahir Yahya ◽  
Muhammad Mustaqim Ahmat
Keyword(s):  
Information Flow ◽  
Simulation Software ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Production Flow ◽  
Cycle Times ◽  
Value Stream ◽  
Aircraft Manufacturing ◽  
Current State ◽  
Manufacturing Company

The purpose of this study is to develop a value stream mapping for a production in an aircraft manufacturing company. The process begins with creating a current state map and understands the production flow and the current cycle times. This provides the information needed to produce a future state map. The goal is to identify and eliminate the waste, which is any activity that does not add value to the final product, in the production process. In order to collect the information needed, the study was conducted within the production facility to enable the researcher gained knowledge and familiarized with the production flow and the activities being performed at the shop floor. Parameters such as cycle times, down times, work in process (WIP) for inventory and material, and information flow paths were recorded. This information will enable the researcher to visualize the current state of the process activities by mapping the material and information flow and looking for opportunities to eliminate wastes. ARENA simulation software package was used to simulate and analyze the process flow and times. Result from the analysis shows that there are areas where the company can further improve their production system. The results show the improvement of the cycle time up to 22% based on the new proposed arrangement of the layout. Therefore the propose layout will be guided to the company in order to improve their production.

scholarly journals Production flow improvement and value stream mapping in a lean manufacturing world

2021 ◽  
Vol 6 (1) ◽  
pp. 036-050
Author(s):  
Muhammad Adib Uz Zaman ◽  
Emad Rabiei Hosseinabad
Keyword(s):  
Lean Manufacturing ◽  
Performance Metrics ◽  
Value Stream Mapping ◽  
Production Flow ◽  
Value Stream ◽  
Assembly Simulation ◽  
Kaizen Events ◽  
Load Leveling ◽  
And Performance ◽  
Flow Improvement

The importance of lean manufacturing concepts has been discussed many times over the few decades. The most important elements in lean manufacturing practices are value stream mapping (VSM), Kaizen events, load leveling (heijunka), etc. In this case study, a real-world clock assembly simulation has been used to study the performance improvement in terms of production flow and lead time after introducing lean concepts. In each round of simulation, the lean concepts have been introduced one by one and performance metrics were recorded. After implementing the concepts, the productivity was improved enormously. So, this simulation study emphasizes the importance of continuous improvement of production flow through lean concepts in a real production setting.

Development of Computerize Value Stream System

2014 ◽  
Vol 915-916 ◽  
pp. 1405-1411
Author(s):  
A.N.A. Ahmad ◽  
Sulaiman Hj. Hasan ◽  
H. Norafifah
Keyword(s):  
Lean Manufacturing ◽  
Mapping Method ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Traditional Concept ◽  
Value Stream ◽  
Stream System ◽  
Manufacturing Company ◽  
Value Streams ◽  
Individual Value

Value stream mapping (VSM) was initially developed to use of the suite of tools to help researcher or practitioner to identify waste in individual value streams and find an appropriate method to its removal. The process itself is simple and straightforward is used to identify waste using lean manufacturing technique, determined causes of the waste through the value stream mapping method and to propose solution to improve workplace environment. In this project is made an attempt to computerize the process though the application of VSM. Computerize value stream system is basically a method which is an internet networking system combining traditional concept of value stream mapping method to be used at manufacturing company to reduce wastes. This paper summarizes the way to develop an internet, online and network based of an efficient computerize value stream system to improve operation value of the manufacturing company. This paper reviews the design of package that will replace the manual method of doing VSM. This package will be applied in a real shop floor environment.

Lean Manufacturing Implementation in a Gear Shaft Manufacturing Company Using Value Stream Mapping

2015 ◽  
Vol 21 ◽  
pp. 231-237 ◽  
Author(s):  
S. Nallusamy
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Manufacturing Company

Nowadays, Lean manufacturing application is reported for manufacturers in global level.Those reports have exposed that this application has enabled the companies to become competitivethrough the elimination of wastes while producing products and offering services. Various tools like5S, Poka Yoke, Kaizen, Kanban, JIT, etc have been used while implementing lean manufacturingmodel in various types of organization. Recently, both researchers and practitioners have found thatValue Stream Mapping (VSM) technique serves as a powerful vehicle in enabling organizations toimplement lean manufacturing model. Meanwhile, it is found that lean manufacturing model is yet tobe applied in the case of certain manufacturing products. One among those products is gear shaft. Inthis background the theoretical proposition of implementing lean manufacturing model in the case ofmanufacturing a gear shaft has been investigated in this article.

The Analysis of a Production Flow with the Help of Value Stream Mapping

2019 ◽  
Vol 957 ◽  
pp. 203-210
Author(s):  
Ana Gavriluță
Keyword(s):  
Lean Manufacturing ◽  
Lead Time ◽  
Entry Point ◽  
Added Value ◽  
Financial Resources ◽  
Value Stream Mapping ◽  
Production Flow ◽  
Flow Mapping ◽  
Value Stream

The main aim of Lean Manufacturing concept is to produce more with less: space, stock, workforce and time. The companies that along the years implemented Lean Manufacturing, reached a spectacular development, mainly because with the same workforce and financial resources, succeeded to increase significantly their profit (some reached up to 300-400% increase). The strength of Lean concept is the calculation of value of product for the final client, considering each stage of manufacturing. Therefore, the main aim of this paper is to analyze and improve the manufacturing flow of a component, from the system entry point to its exit using Flow Mapping and Value Stream Mapping. After all the actions on improving the flow, the activities without added value decreased with 15.92% and the lead time with 15.61%

scholarly journals Penerapan Lean Manufacturing dengan Metode VSM dan FMEA untuk Mereduksi Pemborosan Produksi Sarden

2020 ◽  
Vol 13 (1) ◽  
Author(s):  
Haris Dwi Armyanto ◽  
Dwi Djumhariyanto ◽  
Santoso Mulyadi
Keyword(s):  
Production Process ◽  
Failure Mode ◽  
Waiting Time ◽  
Lean Manufacturing ◽  
Waiting Times ◽  
Raw Material ◽  
Value Stream Mapping ◽  
Production Flow ◽  
Value Stream ◽  
Current State

CV.X merupakan salah satu perusahaan pengolahan sarden yang terletak di Banyuwangi. Pada proses produksi di perusahaan masih ditemukan beberapa pemborosan (waste). Untuk mengurangi pemborosan yang terjadi digunakan pendekatan lean manufacturing dengan metode Value Stream Mapping (VSM) untuk pemetaan aliran produksi dan aliran informasi terhadap proses produksi dari awal bahan baku hingga produk jadi dan dikirim ke konsumen, serta analisis dengan metode Failure Mode and Effects Analysis (FMEA) untuk mengetahui penyebab kegagalan proses yang paling prioritas dan perlu dilakukan perbaikan dengan segera. Identifikasi pemborosan diawali dengan penggambaran current state map, lalu dilakukan analisis pemborosan ke dalam kategori 7 pemborosan [1]. Pada analsis tersebut ditemukan 3 jenis pemborosan yaitu waiting time, unnecessary inventory dan defect (kembung). Setelah itu dilakukan analisis akar penyebab timbulnya pemborosan menggunakan fishbone diagram, dan analis FMEA untuk mengetahui nilai RPN tertinggi yang selanjutnya akan menjadi prioritas pemberian usulan perbaikan yang tepat dan sesuai dengan masalah dan kondisi proses produksi sarden 125g di CV.X. Rekomendasi perbaikan yang diberikan terhadap pemborosan dengan nilai RPN tertinggi antara lain Menambahkan mesin pencuci produk untuk mengurangi penumpukan produk dan waktu tunggu yang ada sehingga pemborosan waiting time dan unnecessary inventory dapat berkurang, mengganti sarung tangan kain dengan lateks, serta menjaga kebersihan nampan ikan. CV.X is a sardine processing company located in Banyuwangi. In the company production process there are some wastes. To reduce the waste that occurs, lean manufacturing approach using Value Stream Mapping (VSM) method is used to map the production flow and information flow to the production process from the beginning of the raw material to the finished product and sent to consumers, as well as analysis using the Failure Mode and Effects Analysis (FMEA) method. ) to find out what causes the most priority process failures and needs immediate improvement. Waste identification is preceded by a depiction of the current state map, then waste analysis is conducted into category 7 waste. In this analysis, there are 3 types of waste, which are waiting time, unnecessary inventory and defects. After that an analysis of the root causes of waste occurs using fishbone diagrams, and FMEA analysts to find out the highest RPN value which will then be prioritized for giving recommendations for an appropriate improvement and in accordance with the problems and conditions of the 125g sardine production process in CV.X. Improvement recommendations given for waste with the highest RPN value include adding a product washer to reduce product buildup and waiting times so that waiting time and unnecessary inventory waste can be reduced, replacing cloth gloves with latex, and keeping the fish tray clean.

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