VSM in Aid of Automotive Industry’s Lean Operations: A Case Study
Keywords:
Lean production, VSM, Takt- Time and KanbanAbstract
The road map to competitiveness journeys through making all- round improvements in production planning, processes, and practices. Endeavors include elimination of all non- value- adding costs and redundancies while affecting possible reduction in lead times, inventories etc. Such redundancies in operations are identified by the lean tool termed as Value Stream Mapping (VSM), which helps visualize both product flows, through various workstations, as well as the information flows (used to control the product flows). VSM thus helps chart the manufacturing environment, by flowing the product at the pull of the customer, which is carried out in pursuit of perfection through continuous improvement. Using VSM many organizations have hitherto changed their existing layouts, material handling systems, inventory control to reduce the lead- time and work- in- process (WIP) inventories.
The present work describes the application of value stream mapping in an automotive company with a focus on piston rings machining operations. The case study reveals the various gap areas in the manufacture of piston rings for automobiles with aid of Value Stream mapping and subsequently the use of Lean tools applicable for more responsive operations, lead- time reductions and lowering inventories. Deployment of such lean studies is seen to be lacking in most of the automotive parts manufacturing companies.
References
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2. Thareja P. Stephen Covey Becomes A Foundryman!. FOUNDRY Sept/Oct 2002: 73-78.
3. Thareja P. Lean Founding For Green, Serene And Quality Foundry. FOUNDRY Nov/Dec 2005; XVII(6): 73-78.
4. Thareja P. Lean To Green for Competence. Lecture notes, AICTE sponsored Staff Development programme on LEAN Manufacturing. 11th Dec 2008.
5. Thareja P, Sharma A. Lean Learning?. Journal of Production Research & Management 2013; 3(3).
6. Thareja P. Manufacturing Ordeal And Challenges To Energy-Environment-Society Infrastructure. Journal Of Education In Engineering And Technology Jan-June 07; 1(1): 46-52.
7. Thareja P. Alignment to the Bull, A Total Quality Organization Thro’ People, (Part 35). FOUNDRY A Journal of Progressive Metal Casters Sep / Oct. 2011; xxiii(137).
8. Thareja P, Mahapatra PB, Sharma DD. Metamorphosis In Teaching Of ‘Materials’: A Case Study Aligning Manufacturing Requirements. National Seminar on Advances in Materials & Manufacturing Processes AMMT -07, Punjab Engineering College, Chandigarh 21- 22 Sept 2007.
9. Thareja P, Thareja M. Total Environmental Management: Journey To A Green Globe. Quality World February 2010; VII(2): 3- 7.[adapted from Consultancy Vision, Special Issue on Environment, CDC April 2006] Available at :http://papers.ssrn.com/sol3/papers.cfm?abstr act_id=1505965.
10. Thareja P. Holean Education – A Roadmap To Sustainable Education, presented at 8th National Conference on Sustainable Development Role of Engineers and Technologists, New Delhi, 29th Nov 2010.
11. Klotz L, Horman M, Bodenschatz M. A Lean Modeling Protocol for Evaluating Green Project Delivery. Lean Construction Journal 2007; 3(1). ISSN: 1555-1369. Available at: www.leanconstructionjournal.org.
12. Tapping D, Luyster T, Shuker T. Value Stream Management Eight Steps to Planning,Mapping and Sustainining Lean Improvements. New York, NY: Productivity, Inc, 2002.
13. Bamber L, Dale BG. Lean Production: A Study Of Application In Traditional Manufacturing Environment. International Journals Of Production Planning And Control 2000; 11(3): 291-98.
14. Wee HM, Wu S. Lean supply chain and its effect on product cost and quality: a case study on Ford Motor Company. Supply Chain Management: An International Journal 2009; 14(5): 335-41.
15. Morgan J. High Performance Product Development: A Systems Approach to a Lean product Development Process. PhD Diss., University of Michigan, Ann Arbor, MI, 2002.
16. Mcmanus HL, Richard LM. Value Stream Analysis And Mapping for Product Development. Proceedings Of The International Council Of The Aeronautical Sciences 23rd Icas Congress, 8-13 September, 2002, Toronto Canada. 17. Hines P, Nick R, Ann E. Value Stream Mapping: A Distribution Industry Application. Benchmarking: An International Journal 1999; 6(1): 60 – 77.
18. Zidel TG. A Lean Guide To Transforming Healthcare, American Society Of Quality, Milwaukee, Wisconsin: ASQ Quality Press, 2006.
19. Emiliani ML, Stec DJ. Using Value-Stream Maps To Improve Leadership.Leadership & Organization Development Journal 2004; 25(8).
20. Sarkar D. Lean For Service Organizations And Offices, American Society Of Quality, Milwaukee, Wisconsin: ASQ Quality Press, 2008.
21. Serrano I, Ochoa C, de Castro R. Evaluation of value stream mapping in manufacturing system redesign. Int J Prod Res 2008; 46(16):4409–30. doi:10.1080/00207540601182302.
22. Buruiana F, Coelho MBAG, Epureanu A et al. Value Stream Map and Kaizen Concept Implemented in a Shaft Manufacturing Chain. The annuals of “Dunarea De Jos” University of Galati Fascicle V, Technologies in Machine Building, 2009: 1221-66.
23. Chen JC, Cheng CH, Huang PB. Supply chain management with lean production and RFID application: A case study. Expert systems with applications 2013; 40(9): 3389- 97.
24. Levinson WA, Rerick RA. Lean Enterprise: A Synergistic Approach To Minimizing Waste. Milwaukee, Wisconsin: ASQ Quality Press, 2002.
25. Hines P, Taylor D. Going Lean. Cardiff, UK: Lean Enterprise Research Centre Cardiff Business School, 2000.
26. Thareja P. A Total Quality Organisation Through People: (Part 13 ) Competent Intrapreneurship. FOUNDRY, An Indian Journal For Progressive Metal Casters Jan/Feb 2008A; XX(1): 61 – 68.
27. Hayes RH, Clark KB. Why Some Factories Are More Productive Than Others. Harvard Business Review 1986; 64(5): 66-73.
28. Thareja P, Singh KP. Improving Competitiveness Of An Induction Furnace Unit. Proceedings Of 47th Indian Foundry Cogress and 6th Asian Foundry Congress, Calcutta, 1999.
29. Thareja P. A Total Quality Organisation Through People: (Part 18): 8-D Ate My Problems). FOUNDRY, An Indian Journal For Progressive Metal Casters Nov/Dec 2008B; XX(6): 41-48.
30. Braiden BW, Morrison KR. Lean Manufacturing Optimization Of Automotive Motor Compartment System. Computers And Industrial Engineering 1996; 31(1/2): 99- 102.
31. Abdullah F. Lean Manufacturing Tools and Techniques in the Process Industry with a Focus on Steel. Ph.D. dissertation, University of Pittsburgh, PA, 2003.
32. Pavnaskar SJ, Gershenson JK, Jambekar AB. Classification Scheme For Lean Manufacturing Tools . International Journal Of Production Research 2003; 41(3): 3075- 90.
33. Abduelmula A, Wagner C. Design And Evaluation Of Lean Manufacturing Cells: A Simulation Model (Industrial Engineering Department), 2001. Available at: Http://Www.Iamot.Org/Conference/Index.Ph p/Ocs/4/Paper/View/1066/454.
34. Womack JP, Jones DT. Lean Thinking : Banish Waste And Create Wealth In Your Corporation., Simon And Schuster, UK, 2003
35. Hopp WJ. Spearman ML. Factory Physics: Foundations of Manufacturing Management, 2nd (ed.), McGraw Hill, New York, NY, 2000.
36. Thareja P. A Total Quality Organisation Through People: (Part 10) Leading Foundries From The Bottom. FOUNDRY, An Indian Journal For Progressive Metal Casters July/Aug 2007 B; XIX(4).
Published
2019-01-07
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