Journal Press India^®

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‘Lean’ is an established industrial paradigm with proven track record in various sectors of the industry (Womack and Jones, 1996). World-Class multinational companies such as Toyota (second biggest global car manufacturer), Porsche’s (most profitable Global OEM), Boeing (largest global aerospace business) and Tesco (third largest global retailer) have adopted Lean at the Corporate level. It is an applied methodology and step by step technique that results work tasks in a process to be performed with the least involvement of non-value adding activities greatly resulting in reduced process time, wait time, queue time, operation time, move time, administrative time and other delays. This paper addresses the implementation of Lean Manufacturing in a small scale production industry. The main objective of this practice was to minimize the waste on the shop floor. This paper shows the application of Value Stream Mapping (VSM) in detail. By identifying the waste and its sources the present and future states of value stream maps are developed to improve the production. This improvement technique focuses the benefits of Lean production techniques in various stages of V.M. Auto Parts Pvt. Ltd. and results 6-7% potential cost saving reduction in cycle time and increase in cycle efficiency is guaranteed. The flow process or cycle time was enhanced thus minimizing various non value added actions and times such as bottle necking time, waiting time, material handling time, etc. More generic approach to design lean environment can be developed by this case study.

Keywords

Lean Manufacturing; Value Stream Mapping; Ccycle Time; Takt Time Cycle Efficiency

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