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.