Sustainability via value stream mapping – A Lean study in Genset industry

Abstract

Sustainability is the future of management and lean manufacturing (LM) occupies a key part in reducing wastes in any industrial organization. Any sustainable practice adapted in the manufacturing industry would deliver a large scale value and benefits above the cost paid by the consumers. The triple bottom approach of people, planet and profits are also met in such value adding activities. Value stream mapping (VSM) is the key tool in LM which facilitates in recognizing waste in materials and information stream in a precise product group. The aim of this project is to demonstrate the prominence of VSM in the chosen power generation industry in enhancing the productivity and its business strategy. A case study approach is followed to demonstrate the significance of VSM in identifying and redesigning a lay out to increase the daily shift production of units from eight units to twelve units in the Genset Manufacturing Assembly. The study has been executed by applying seven critical steps. The method syndicates multidimensional process mining (MDPM) methods with verified principles of VSM and lean process. An assembly unit is identified where the existing layout needs enhancement based on the customer demand and top-level management. The overall activities with structure are mapped by means of process flowchart and new layout was developed. It was carried out by a cross-functional team and critical analysis was done. The cross functional group has completed a viability study on implementation of suggested layout by conducting time study, Video analysis and work study to design New layout. Finally, new Layout resulted in demonstrating practicability of the VSM strategy to make effective genset manufacturing assembly.