Application of Lean Manufacturing using Value Stream Mapping in a Medium Scale Organization: A Case Study By Jashanpreet Singh
Abstract
Value Stream Mapping (VSM) is an important tool under lean philosophy. These days, the market is emerging fast so the manufacturers need more accuracy, minimum time and least workforce. A case study has been conducted in manufacturing unit. The unit is manufacturing the juicers, mixers, grinders, salad cutting, lassi machines etc. The main component in this juicer machine is pillar rod. VSM methodology was being used in this manufacturing unit. The current state map was made by doing personal survey and interaction, considering TAKT time as main parameter. By introducing the Band Saw Machine in the process, the improvements were made in the manufacturing unit that leads to reduction in cutting time to 50%. Another improvement was made in packaging department, wherein the focused was kept on removal of wastage. By incorporating the new plant layout with minimum changes, a future state map was made. On the basis of both current and future state map, it was observed that lead time of the component selected has been reduced by 14.88%, processing time by 13.45%, wastage of material`s movement by 37.97%. As proposed in model, the Work-in-Process (WIP) inventory has been reduced by 17.76% and workforce by 17.64%. Further it would lead to the profit of Rs.143200 per annum.
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