Application of value stream mapping for reduction of cycle time in machining process
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This Case Study deals with implementation of lean manufacturing techniques in crankshaft manufacturing system at an automotive manufacturing plant in South India. Lean Manufacturing was selected to meet the quality, cost and delivery targets. After Implementing lean manufacturing, manufacturing lead time reduced by 40%, defects were reduced, high process capability achieved, quick response to customer demands.
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The document provides an overview of Lean manufacturing and the Toyota Production System. It discusses how Toyota implemented Lean principles beginning in the 1950s to become highly efficient and profitable. The core concepts of Lean include eliminating waste, reducing lead times, and continuous improvement. Lean aims to optimize flow and pull production using tools like just-in-time, standard work, and visual management. Kaizen events are used to rapidly improve processes by multidisciplinary teams identifying and eliminating sources of waste.
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This document provides information on value stream mapping (VSM), including:
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2. There are three main types of value streams: raw material to finished product, concept to launch, and order to cash.
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3. A current state map visually depicts the actual state of the current process flow, including metrics like cycle times and changeover times.
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Recorded webinar: http://bit.ly/1uVqMJC
Subscribe: http://www.ksmartin.com/subscribe
Purchase the book: http://www.bit.ly/VSM
These are slides from a webinar done with APICS Heartland on the topic of Value Stream Mapping.
This webinar covers:
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• How to plan for a value stream mapping activity
• The mechanics of mapping, including key metrics
for office/service/knowledge work
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Value stream mapping is a practical and highly effective way to learn to see and resolve disconnects, redundancies, and gaps in how work gets done.
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Download full presentation from this link
https://www.file-up.org/0xeluavoxddj
for more inquiries contact me at shadymagdy@windowslive.com
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Recorded webinar: http://bit.ly/1uVqMJC
Subscribe: http://www.ksmartin.com/subscribe
Purchase the book: http://www.bit.ly/VSM
These are slides from a webinar done with APICS Heartland on the topic of Value Stream Mapping.
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for office/service/knowledge work
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Value stream mapping is a practical and highly effective way to learn to see and resolve disconnects, redundancies, and gaps in how work gets done.
This VSM project template helps you and your project team to put together a "storyboard" for effective presentation to your key stakeholders. It includes four key phases:
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3) Develop a future state map
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Kaizen events are short, focused improvement projects that aim to drive quick changes and lead to a leaner business. They use a team-based approach over a short time period, such as 5 days, to identify problems and implement solutions. Key elements include establishing clear goals, dedicating resources to the event, focusing on implementation and action, and achieving immediate, measurable results. Successful kaizen events require planning, stakeholder engagement, change management strategies to sustain results, and defining the current and future states.
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Assembly line balancing
Download full presentation from this link
https://www.file-up.org/0xeluavoxddj
for more inquiries contact me at shadymagdy@windowslive.com
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very cost efficient process if applied in proper manner.
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Application of value stream mapping tool to reduce wastes in bearing industry
In today’s highly competitive business environment, companies require improvement in Production Lead
Times, costs and customer service levels to survive. Because of this, companies have become more
customers focused. The result is that companies have been putting in significant effort to improve their
efficiency.
This paper present the practical application of Value Stream Mapping (VSM) tool implement in a bearing
industry. A value stream is an assortment of all actions (value added as well as non-value added) that are
required to bring a product through the essential flows, starting with raw material and ending with the
customer. For drawing current state value stream mapping, all relevant data has been collected and analyzed. Then analysis of current state map has been done for identifying non-value adding activities, in
other words waste and suggestions on how to remove or reduce different wastes. From the results achieved
by current VSM, it was observable that the two processes Annealing and CNC Machining have higher cycle
time and WIP. In order to increase their capacity, their cycle should be reduced.
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D_David_ Thompson_resume_15_1
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Overview on Kanban Methodology and its Implementation
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PRODUCTION AND OPERATIONS MANAGEMENT (304) SEM3 NOV2021.pdf
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Application of value stream mapping for reduction of cycle time in machining process
- 1. Application of Value Stream Mapping for Reduction of Cycle Time in a Machining Process Sumit Bhattacharya 851 Sathish Kumar 863
- 2. Abstract • This Case Study deals with implementation of lean manufacturing techniques in crankshaft manufacturing system at an automotive manufacturing plant in South India. • Lean Manufacturing was selected to meet the quality, cost and delivery targets. • After Implementing lean manufacturing, manufacturing lead time reduced by 40%, defects were reduced, high process capability achieved, quick response to customer demands.
- 3. Problems in existing system • High Additional processing time • More number of workers • Consumes more resources • More inventory • More scrap • High Cycle time
- 4. Earlier System Outline • Earlier it was manufactured in three different location • Movement in zig-zag pattern • Poor communication • Unbalanced work content
- 5. New Outline after Implementation • Zig-Zag flow eliminated • Unidirectional • Better communication • Operator requirement less • Well organized
- 6. Value Stream Mapping • Method of lean manufacturing which uses symbols, metrics and arrows to show and improve flow of inventory and information required to produce a product or service. • Value stream mapping allows one to determine where the waste occurs. • This helps in identifying various factors: Value added time, Non Value added time, cycle time, changeover time. • This helps in identifying and eliminating waste.
- 7. Current Value Stream Mapping State
- 8. Future State after implementation
- 9. • KAIZEN 1: Implement the Modified Process by eliminate and combine operation. • KAIZEN 2: Implement the modified process by optimizing the process parameters. • KAIZEN 3: Implement the modified process by tooling improvement and introduce CNC lathe.
- 10. Results after Implementation • Single piece flow for crankshaft manufacturing system was established. • The non- value adding activities were eliminated • Quick response to customer demand to supply frequently in small lots • Complete manufacturing was established to meet customer requirements and quality.
- 12. Conclusion • Implementation of Lean Manufacturing in crank shaft manufacturing cell would eliminate the 8 non-value adding wastes like over production, waiting, unnecessary transport movement, defects and unused employee creativity. • This would also improve the flexibility of the production process.
- 13. References 1. K. Venkataramana, B.Vijaya Ramnath, V.Muthu Kumar, C.Elanchezhian, 2014 ‘Application of Value Stream Mapping for Reduction of Cycle Time in a Machining Process’, 3rd International Conference on Materials Processing and Characterisation.