Application of Value Stream Mapping for Reduction of Cycle Time in a Machining
Process
Sumit Bhattacharya 851
Sathish Kumar 863
Abstract
• This Case Study deals with implementation of lean manufacturingtechniques in crankshaft manufacturing system at an automotivemanufacturing plant in South India.
• Lean Manufacturing was selected to meet the quality, cost and deliverytargets.
• After Implementing lean manufacturing, manufacturing lead timereduced by 40%, defects were reduced, high process capabilityachieved, quick response to customer demands.
Problems in existing system
• High Additional processing time
• More number of workers
• Consumes more resources
• More inventory
• More scrap
• High Cycle time
Earlier System Outline
• Earlier it was manufactured inthree different location
• Movement in zig-zag pattern
• Poor communication
• Unbalanced work content
New Outline after Implementation
• Zig-Zag flow eliminated
• Unidirectional
• Better communication
• Operator requirement less
• Well organized
Value Stream Mapping
• Method of lean manufacturing which uses symbols, metrics andarrows to show and improve flow of inventory and informationrequired to produce a product or service.
• Value stream mapping allows one to determine where the wasteoccurs.
• This helps in identifying various factors: Value added time, Non Valueadded time, cycle time, changeover time.
• This helps in identifying and eliminating waste.
• 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.
Results after Implementation
• Single piece flow for crankshaft manufacturing system wasestablished.
• The non- value adding activities were eliminated
• Quick response to customer demand to supply frequently in small lots
• Complete manufacturing was established to meet customerrequirements and quality.
Conclusion
• Implementation of Lean Manufacturing in crank shaft manufacturingcell would eliminate the 8 non-value adding wastes like overproduction, waiting, unnecessary transport movement, defects andunused employee creativity.
• This would also improve the flexibility of the production process.