An Approach to Reduce Production Lead Time in the Valve Manufacturing Industry

Abstract:

Lean manufacturing aids improved productivity and product quality by identifying and eliminating waste. The present work aims to utilize Value Stream Mapping (VSM), a lean manufacturing technique to minimize the cycle time in the production of valves. A current state map is developed with available information gathered from the production unit, to identify the time-consuming factors like waiting time, improper inspection, and the lack of material and resources for manufacturing. Problem-solving techniques like 5s, JIT, KANBAN, and KAIZEN are used to reduce time-consuming activities. Value-Added and Non-value-added activities are identified through Current State Map. Activities such as placing a purchase order, drawing, assembling, testing, packaging, and shipping are Value-added activities. Non-Value-added activities are identified as rework, inspection, movement, waiting for the next process, and over-processing. The job waiting time between the next process is reduced by 70% using the future state map and the productivity is enhanced.

• Periodical: Applied Mechanics and Materials (Volume 920)
• Pages: 167-174
• DOI: https://doi.org/10.4028/p-Pna0AC
• Online since: March 2024
• Authors: M. Thirumalaimuthukumaran*, V.R. Muruganantham
• Keywords: Current State Map, Future State Map, Non-Value Added Activities, Productivity, Value Addedactivities, Value Stream Map

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