Implementation of Lean Manufacturing through Value Stream Mapping

This research has been carried out to implement the Lean manufacturing in manufacturing unit through value stream mapping i.e. tool of Lean Manufacturing. Value Stream mapping being an effective Lean tool has emerged as the preferred way to identify and eliminate waste, through continuous improvement in almost every type of production business. This research aims at studying on how value stream mapping can be applied to a manufacturing business, in specification to the company manufacturing electric Monoblock Pumps. This research starts with the concept of integration of lean techniques with manufacturing and results in positive response with significant reduction in lead times. The process is first drawn to reflect current state of the electric monoblock pump line then analyzed for opportunities. This also includes identification of various bottlenecks, value added and non value added work content in all activities, so as to minimize the waste. The operation analysis recovered problems that exist in the process and various opportunities for improvement are highlighted with suitable suggestions. Thereby the value stream is rearranged to obtain an optimized process flow i.e. future state. The research concludes with a result that the implementation of future state value stream map can give a significant reduction in the current lead time up to 51% for highly inefficient work station and an average reduction of about 25% for complete shop floor. Various recommendations are also given to improve the current operations within the company limitations.