Study of Lean Production System Using Value Stream Mapping in Manufacturing Sector and Subsequent Implementation in Tool Room

Batra, Rushil; Nanda, Sahil; Singhal, Shubham; Singari, Ranganath M.

doi:10.4271/2016-01-0342

Cited by 11 publications

(3 citation statements)

References 17 publications

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“…The way one manufacturer uses LM tools and techniques to manufacture a product will not work for another organization, and indeed implementing lean principles require creativity and a deep knowledge of a company’s operations and culture as much as it requires keen and thorough analysis. Therefore, as Batra et al (2016) and Bhasin (2012) suggest organizations with various sizes encounter different barriers to implement LM and use VSM, so the other useful study could be replication of this study in manufacturing organizations with different sizes (Dadashnejad and Valmohammadi, 2017) to provide a benchmarking basis for other organizations interested in implementing LM philosophy and VSM tool in the country.…”

Section: Limitationsmentioning

confidence: 96%

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Investigating the effect of value stream mapping on operational losses: a case study

Dadashnejad

Valmohammadi

2018

JEDT

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Purpose One of most important tools for lean production is value stream mapping (VSM), which identifies and reduces errors, losses, waiting time and improves value adding time, leading to enhanced product quality through empowering production unit in terms of production risk and cost reduction in the long term. This paper aims to present a general concept for production flow, such that value stream can be fully understood. For this purpose, this research investigates the effect of value stream on operational losses and analyzes the process that has been conducted in preview step operationally, using the discovered pattern. Design/methodology/approach In this research, related processes were evaluated after the review of the relevant literature and after extracting operational basics of lean approach using a questionnaire, such that all factors affecting operational losses and VSM were assessed. Then comparison between the result of current state map and the result of future state map were done and analyzed. Cronbach’s alpha was calculated to test the designed questionnaire’s reliability, which resulted in an acceptable level of 0.845. The structural equation modeling method through SPSS and Smart–Partial Least Square was applied to analyze the data and test the hypotheses. Findings The results reveal that implementing required changes and corrections will lead directly to production process improvement, which, in turn, results in higher customer satisfaction because of cost reduction and quality enhancement. Also, tests of the hypotheses confirm that VSM affects six operational losses, namely, equipment failures, set-up and changeovers, idling and minor stoppages, reduced speed operation, scrap and rework and startup losses. Research limitations/implications Though this study was done in a single manufacturing company, the implementation of this study delivers important results that can be deployed in other such manufacturing companies. Practical implications This tool helps to identify loss points, make right decisions, and choose the best methods and lean tools for improvement. The surveyed company can integrate lean principles and tools and achieve better results using this tool. Also, this tool could be used to analyze the process and to define necessary changes before changing the process components. Originality/value This study contributes to the body of knowledge in manufacturing research as the study regarding the effects of improvement opportunities identified through VSM on operational losses is still something new.

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Section: Limitationsmentioning

confidence: 96%

“…In their study, Batra et al (2016) attempted to investigate the significance of VSM in lean transformation of manufacturing units and to apply VSM in a tool room. They argue that VSM is an essential tool used to interpret both material and information flow in a system.…”

Section: Literature Review and Hypothesesmentioning

confidence: 99%

Investigating the effect of value stream mapping on operational losses: a case study

Dadashnejad

Valmohammadi

2018

JEDT

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“…The main aim of lean tools is to remove this 3M from the organization [1].The first step to implement lean manufacturing tool in any organization is to apply Value Stream Mapping (VSM) [2]. A value stream is a combination of value added and non-value added activities that are required bring a product through the essential flows; starting with raw material and ending with the customer for reducing the production wastes [3].…”

Section: C) Kanbanmentioning

confidence: 99%

Untitled

2019

IJAPIE

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In this research paper, we have used lean tools that are applicable in various faster growingindustries like FMCG, pharmaceuticals; hospitality, manufacturing etc are used. The tool that is given the priority over others in identifying the waste is Value stream mapping. Value stream mapping is a lean tool that is used to translate both information and flow of data through which those processes that are not adding any positive value in our study can be easily eliminated. This paper is an effective effort to find out the waste production during manufacturing of a perishable goods in discrete manufacturing system. Pareto chart has been used to categories the factors that are responsible for the 80 percent of waste. Here Ishikawa diagram has played a vital role for finding of their possible causes and effect. Other contemporary lean tools like Kanban, Kaizen, and FIFO are used for future state map processing. The result obtained through the future state value stream map states the changeover time of various processes, the cycle time near to the takt time, improvement in lead time and total cycle time of the manufacturing process.

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A brief review on various effects of surface texturing using lasers on the tool inserts

Nagpal

Rana

Lal

et al. 2022

Materials Today: Proceedings

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Study of Lean Production System Using Value Stream Mapping in Manufacturing Sector and Subsequent Implementation in Tool Room

Cited by 11 publications

References 17 publications

Investigating the effect of value stream mapping on operational losses: a case study

Investigating the effect of value stream mapping on operational losses: a case study

Untitled

A brief review on various effects of surface texturing using lasers on the tool inserts

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