Application of VSM in Manufacturing Industry: A Case Study

Value Stream Mapping is a simple process of directly observing the flows of information and materials as they now occur summarizing them visually and then envisioning a future state with much better performance. This helps in planning and linking lean initiatives through systematic data capture and analysis. This unique mapping concept helps to visualize the station cycle times, inventory at each stage and information flow across the supply chain. Present study is an attempt to identify and eliminate different types of wastes with the application of value stream mapping in a production industry. Three products (Equalizer beam, Cam shaft and Crank shaft gear) used in railway engine have been selected for study. The current (or 'as is') status is mapped to capture a snapshot of how things are done and where the improvement potentials lie. Future or 'to be' state map is also discussed to show how things should to be done considering takt time requirements. The study revealed that a significant improvement is possible in area of lead-time, station cycle time and work in process inventory.