Application of Lean Tools for Reduction of Manufacturing Lead Time

Abstract

In the recent years, manufacturing industries are trying to improve customer service by reducing wastes, reducing lead time, improving quality and improving productivity using lean tools. Value Stream Mapping is one of the lean tools for analyzing the current state and designing a future state for the series of events that take a product from its beginning through delivery to the customer. The goal of this study is to apply Value Stream Mapping in production line of Fuel tank semi trailers at XYZ PLC Metal Industry for reducing the manufacturing lead time. In this case study, the existing state of the production line is mapped with the help of Value Stream Mapping process symbols and the biggest improvement areas like excessive work in process and long lead time are identified. Some improvements in current state Value Stream Mapping are suggested and with these improvements future state Value Stream Mapping is developed. Current state and future state of the production line are compared; the results show that 47.45% reduction in lead time, 50.2% reduction in work in process time, 59.2% reduction in total waiting time, 72.72% reduction in number of work in process products, 7% reduction in number of workers and over 89.65% increase in the yearly throughput of products.