Lean Manufacturing Implementation Using Value Stream Mapping with Simulation to Reduce Cycle Time and Improve Productivity in Valve Manufacturing Unit

Abstract

For any manufacturing unit to outsmart its competitors, it must focus on improving the productivity of its operations and quality of its products, and emphasize on decreasing the delivery time of its products to its customers. This work highlights the minimization of non-value adding activities of steering gear box sub-assembly station in the manufacturing unit and it is done through one of the key tools of lean manufacturing techniques, i.e., Value Stream Mapping (VSM). Firstly, the current state VSM is done, which reveals the unwanted movements of operators. It is observed that a significant amount of non-value adding activities are being carried out by the operators. Prodigious efforts are made in order to reduce the unproductive movements of the operators and suitable remedial measures are encouraged at each section, thereby improving the productivity of the processes. By simulating the model of process on arena software, the suggestions and proposed changes are successfully implemented and future state VSM is done. The results obtained are encouraging. This work will be of immense help to those involved in areas of productivity improvement in a manufacturing unit.