Development of value stream map for achieving leanness in a manufacturing organization

This paper aims to explore the practical feasibility of deploying value stream mapping (VSM) for enabling lean manufacturing.

The literature on lean manufacturing and VSM has been reviewed. VSM has been selected as a technique for solving the problem existing in the case organization. The current state map has been developed after making necessary observations and calculations. Then various improvement proposals have been identified and the future state map has been developed. The simulation approach has been used for validating performance improvements. The practicality of the approach has been validated.

Two kinds of validation are being conducted in the case organization using questionnaire based approach. In the first stage, the practical receptivity of deploying the proposals has been gathered from the executives. In the second stage, statistical validation has been performed.

VSM has been applied for solving the problem in the case organisation. But the organisation has implemented world class strategies such as ISO quality management system and total quality management. Hence, the experiences gained by the conduct of this implementation study are feasible and deployable in similar organisations.

In order to acquire lean characteristics, modern organisations are focussed on the implementation of various lean tools/techniques. The results of the implementation study indicated significant improvement in lean characteristics.

The implementation study reported in this article is an original contribution of the authors which has been conducted in a typical industrial scenario. By the virtue of its research background and practical compatibility, the implementation study is considered to be highly valuable.