Application of Value Stream Mapping for Reduction of Cycle Time in a Machining Process

Abstract

Lean manufacturing initiative is being followed by various organizations in the recent years which mainly focuses on improving the efficiency of operations by eliminating and reducing wastes. This paper aimed to explain the implementation of lean manufacturing techniques in the crankshaft manufacturing system at an automotive manufacturing plant located in south India.. A multi criteria decision making model, analytical hierarchy process is applied to analyze the decision making process in the manufacturing system. The objective of the case industry was to increase the export sales. Lean manufacturing system was selected to meet the company“s quality, cost and delivery targets. Crankshaft was manufactured in a single piece flow system with the low cost machines developed indigenously and the results are that the crankshafts have passed the testing, validation and approval by the customer to produce any variant in the company. After implementing lean manufacturing system, the manufacturing lead time reduced by forty percent, defects were reduced, higher process capability achieved, quick response to the customer demand in small lots were achieved.