USING VALUE STREAM MAPPING FOR LEAN MANUFACTURING IMPLEMENTATION: CEMENT SACKS FACTORY AS AN INDUSTRIAL CASE STUDY

Abstract

Lean manufacturing is a production system, which was first developed by Toyota Production Systems (TPSs) to reduce wastes while improving the operational and environmental performance of manufacturing and industrial businesses. While the global industrial market suffers from gnarled competition, lean manufacturing philosophy is providing an effective methodology to reduce cost and maximize profit. In addition, the market no longer accepts waste caused by out of control production or inefficient processes. A commitment to quality and lean operations will result in quality improvement, waste elimination and reduction in time and costs. Value stream mappings (VSMs), a lean manufacturing tool, which originated from the Toyota Production Systems (TPSs), is known as “material and information flow mapping.” This mapping tool uses the techniques of lean manufacturing to analyze and evaluate certain work processes in a manufacturing operation. This tool is used primarily to identify, demonstrate and decrease waste, as well as create flow in the manufacturing process. VSM can be created merely using paper and pencil; however, more advanced maps are created using Microsoft Visio as well as Microsoft Excel. This paper describes practical implementation strategies for using lean manufacturing and an industrial case study(Cement Sacks Factory) is included. After lean manufacturing methodology has been applied to the case, results are produced as Cement Sacks Factory process efficiency is raised by 4.31% and the TAKT time is reduced about 56%.