Improving Lead Time through Lean Manufacturing

Abstract

Lean manufacturing is a well-established methodology aimed at optimizing production by eliminating waste, enabling industries to thrive in a globally competitive environment. This paper presents a case study of a well-known automotive manufacturing industry focusing on the axle process. This article demonstrates how the Value Stream Mapping (VSM) methodology was used in the axle process to reduce lead time by producing quality products with a reduction in non-value-added activities. The current state of the axle process was mapped using industry data from the past six months. Significant improvements were realized following the successful implementation of VSM, including a reduction in the lead time from 89.50 hours to 50.55 hours. The new state map was also created after implementing the improvements. The results illustrated that the VSM increased the effectiveness of the axle process by 56.48%.

Keywords

• Lean principle
• Process improvement
• VSM
• Waste

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