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Improving Lead Time through Lean Manufacturing

Year 2024, , 849 - 853, 15.09.2024
https://doi.org/10.34248/bsengineering.1489166

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%.

References

  • Atigre PS, Shah AP, Patil VR. 2017. Application of 8D methodology for minimizing the defects in manufacturing process: A case study. IJERT, 6(09): 123-126.
  • Badhotiya GK, Chauhan AS, Yadav A, Kushwaha P, Singh Y. 2023. Application of value stream mapping for waste elimination: A case of construction equipment industry. In AIP Conference Proceedings, August 6-7, Dehradun, India, pp: 21.
  • Banica CF, Belu N. 2019. Application of 8D methodology an effective problem solving tool in automotive industry. Sci Bull Automotive Series, XXV(29): 1-7.
  • Belokar RM, Kumar V, Kharb SS. 2012. An application of value stream mapping in automotive industry: A case study. IJITEE, 1(2): 152-157.
  • Deshkar A, Kamle S, Giri J, Korde V. 2018. Design and evaluation of a lean manufacturing framework using value stream mapping (VSM) for a plastic bag manufacturing unit. Mater Today Proc, 5(2): 7668-7677.
  • Duggan KJ. 2002. Creating mixed model in value streams. Productivity Press, New York, US.
  • Guleria P, Pathania A, Sharma S, Sá JC. 2022. Lean six-sigma implementation in an automobile axle manufacturing industry: A case study. Mater Today Proc, 50: 1739-1746.
  • Jimenez G, Santos G, Sá JC, Ricardo S, Pulido J, Pizarro A, Hernández H. 2019. Improvement of productivity and quality in the value chain through lean manufacturing – a case study. Procedia Manuf, 41: 882-889.
  • Narke MM, Jayadeva CT. 2020. Value stream mapping: Effective lean tool for SMEs. Mater Today Proc, 24: 1263-1272.
  • Rahani AR, Al-Ashraf M. 2012. Production flow analysis through value stream mapping: A lean manufacturing process case study. Procedia Eng, 41: 1727-1734.
  • Ranjan A, Mutra RR, Kirty Y, Srinivas J, Norhisham M, Reddy DM. 2023. Study and failure analysis of non-drive automotive rear axle of heavy commercial vehicle. Int J Heavy Veh Syst, 30(1): 1-16.
  • Rohani JM, Zahraee SM. 2015. Production line analysis via value stream mapping: A lean manufacturing process of color industry. Procedia Manuf, 2: 6-10.
  • Romero LF, Arce A. 2017. Applying value stream mapping in manufacturing: A systematic literature review. IFAC Pap OnLine, 50(1): 1075-1086.
  • Saboo A, Garza-Reyes JA, Er A, Kumar V. 2014. A VSM improvement-based approach for lean operations in an Indian manufacturing SME. IJLER, 1(1): 41-58.
  • Yousaf MU, Aized T, Shabbir A, Ahmad M, Nabi HZ. 2023. Automobile rear axle housing design and production process improvement using FMEA. Eng Fail Anal, 154: 107649.

Improving Lead Time through Lean Manufacturing

Year 2024, , 849 - 853, 15.09.2024
https://doi.org/10.34248/bsengineering.1489166

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%.

References

  • Atigre PS, Shah AP, Patil VR. 2017. Application of 8D methodology for minimizing the defects in manufacturing process: A case study. IJERT, 6(09): 123-126.
  • Badhotiya GK, Chauhan AS, Yadav A, Kushwaha P, Singh Y. 2023. Application of value stream mapping for waste elimination: A case of construction equipment industry. In AIP Conference Proceedings, August 6-7, Dehradun, India, pp: 21.
  • Banica CF, Belu N. 2019. Application of 8D methodology an effective problem solving tool in automotive industry. Sci Bull Automotive Series, XXV(29): 1-7.
  • Belokar RM, Kumar V, Kharb SS. 2012. An application of value stream mapping in automotive industry: A case study. IJITEE, 1(2): 152-157.
  • Deshkar A, Kamle S, Giri J, Korde V. 2018. Design and evaluation of a lean manufacturing framework using value stream mapping (VSM) for a plastic bag manufacturing unit. Mater Today Proc, 5(2): 7668-7677.
  • Duggan KJ. 2002. Creating mixed model in value streams. Productivity Press, New York, US.
  • Guleria P, Pathania A, Sharma S, Sá JC. 2022. Lean six-sigma implementation in an automobile axle manufacturing industry: A case study. Mater Today Proc, 50: 1739-1746.
  • Jimenez G, Santos G, Sá JC, Ricardo S, Pulido J, Pizarro A, Hernández H. 2019. Improvement of productivity and quality in the value chain through lean manufacturing – a case study. Procedia Manuf, 41: 882-889.
  • Narke MM, Jayadeva CT. 2020. Value stream mapping: Effective lean tool for SMEs. Mater Today Proc, 24: 1263-1272.
  • Rahani AR, Al-Ashraf M. 2012. Production flow analysis through value stream mapping: A lean manufacturing process case study. Procedia Eng, 41: 1727-1734.
  • Ranjan A, Mutra RR, Kirty Y, Srinivas J, Norhisham M, Reddy DM. 2023. Study and failure analysis of non-drive automotive rear axle of heavy commercial vehicle. Int J Heavy Veh Syst, 30(1): 1-16.
  • Rohani JM, Zahraee SM. 2015. Production line analysis via value stream mapping: A lean manufacturing process of color industry. Procedia Manuf, 2: 6-10.
  • Romero LF, Arce A. 2017. Applying value stream mapping in manufacturing: A systematic literature review. IFAC Pap OnLine, 50(1): 1075-1086.
  • Saboo A, Garza-Reyes JA, Er A, Kumar V. 2014. A VSM improvement-based approach for lean operations in an Indian manufacturing SME. IJLER, 1(1): 41-58.
  • Yousaf MU, Aized T, Shabbir A, Ahmad M, Nabi HZ. 2023. Automobile rear axle housing design and production process improvement using FMEA. Eng Fail Anal, 154: 107649.
There are 15 citations in total.

Details

Primary Language English
Subjects Industrial Engineering
Journal Section Research Articles
Authors

Ülge Taş 0000-0002-2376-3735

Early Pub Date August 12, 2024
Publication Date September 15, 2024
Submission Date May 24, 2024
Acceptance Date July 24, 2024
Published in Issue Year 2024

Cite

APA Taş, Ü. (2024). Improving Lead Time through Lean Manufacturing. Black Sea Journal of Engineering and Science, 7(5), 849-853. https://doi.org/10.34248/bsengineering.1489166
AMA Taş Ü. Improving Lead Time through Lean Manufacturing. BSJ Eng. Sci. September 2024;7(5):849-853. doi:10.34248/bsengineering.1489166
Chicago Taş, Ülge. “Improving Lead Time through Lean Manufacturing”. Black Sea Journal of Engineering and Science 7, no. 5 (September 2024): 849-53. https://doi.org/10.34248/bsengineering.1489166.
EndNote Taş Ü (September 1, 2024) Improving Lead Time through Lean Manufacturing. Black Sea Journal of Engineering and Science 7 5 849–853.
IEEE Ü. Taş, “Improving Lead Time through Lean Manufacturing”, BSJ Eng. Sci., vol. 7, no. 5, pp. 849–853, 2024, doi: 10.34248/bsengineering.1489166.
ISNAD Taş, Ülge. “Improving Lead Time through Lean Manufacturing”. Black Sea Journal of Engineering and Science 7/5 (September 2024), 849-853. https://doi.org/10.34248/bsengineering.1489166.
JAMA Taş Ü. Improving Lead Time through Lean Manufacturing. BSJ Eng. Sci. 2024;7:849–853.
MLA Taş, Ülge. “Improving Lead Time through Lean Manufacturing”. Black Sea Journal of Engineering and Science, vol. 7, no. 5, 2024, pp. 849-53, doi:10.34248/bsengineering.1489166.
Vancouver Taş Ü. Improving Lead Time through Lean Manufacturing. BSJ Eng. Sci. 2024;7(5):849-53.

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