Abstract
Abstract The objective of this paper is to identify and eliminate waste, reduce process lead time, establish continuous flow to improve manufacturing velocity and to reduce work in process inventory (WIP) for component known as ‘Element’ which consists of ‘Barrel’ and ‘Plunger’, Data collected for two months in a well known auto ancillary unit on various processes was analysed and current state value stream mapping was drawn. The future state value stream was designed to determine the ideal state design for eliminating waste in the process. The velocity ratio for current state and future state value stream were also identified. Velocity ratio will be improved from the present 6.66% to 10.48% in 3 years and the target is set for First Pass Yield to be > 95%
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