Lean manufacturing implementation using value stream mapping as a tool: A case study from auto components industry
Abstract
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.
Keywords
Citation
Vamsi Krishna Jasti, N. and Sharma, A. (2014), "Lean manufacturing implementation using value stream mapping as a tool: A case study from auto components industry", International Journal of Lean Six Sigma, Vol. 5 No. 1, pp. 89-116. https://doi.org/10.1108/IJLSS-04-2012-0002
Publisher
:Emerald Group Publishing Limited
Copyright © 2014, Emerald Group Publishing Limited