VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9th National Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)
Productivity improvement by using value stream mapping in
stainless steel utensils manufacturing industry
Mr. Chinmay Pingulkar
1
(Department of Mechanical Engineering, VIVA Institute of Technology)
Abstract: Value stream mapping is that lean manufacturing tool which helps to improve the productivity for the
area through its detailed mapping. It is the visualize tool which describes the current state map followed by lean
techniques resulting into the final state map that aiming at reduction of the non-value added activities throughout
its phase. One of the most appropriate ways to emerge the productivity for the particular area is through Lean
Manufacturing. This paper illustrates the VSM techniques and its benefits in stainless steel utensils manufacturing
industry The purpose of this paper is to highlight the effective utilization of the VSM tools for process and
productivity improvements
.Keywords - Value stream mapping, Lean manufacturing, productivity
__________________________________________________________________________________
I. INTRODUCTION
Lean manufacturing focuses at striving only for customer value added activities by preventing the non-value added
activities comes into the plays at each of the particular phase in terms of customer perspective [1]. Working from
the customer’s perspective, who consumes the end products or services, value can be defined as any action or
process that a customer would be willing to pay for. Lean manufacturing is a management philosophy derived
mostly from the Toyota Production System (TPS). TPS is renowned for its focus on reduction of the original
Toyota seven wastes to improve overall customer value, but there are varying perspectives on how this is achieved
to its best [2]. These seven wastes includes Overproduction, Defects, Inventory and Inappropriate Processing,
Excessive transportation, Waiting and Unnecessary motion. A value stream map is said to be an end-to-end
collection of processes or activities involves, that creates value from the customer’s perspective. A value stream
usually quotes list of things such as people, tools and technologies, physical facilities, communication channels
and policies and procedures. A value stream is all the actions i.e. both value added and non-value added, currently
required to bring a product family through the main flows essential to every product: (a) the production flow
transforming from raw material into the hands of the customer, and (b) the design flow from concept to launch.
Standard terminology, symbols, and improvement methods allows VSM to be used as a communication tool for
both internal communication and sharing techniques and results with the larger lean community[3]. Value stream
mapping differs from conventional recording techniques, as it quotes the information at each and every stations
about station cycle time, uptime or utilization of resources, setup time, WIP inventory, manpower requirement
and the information flow from raw materials to finished goods. Value is from the customer’s perspective and the
customer is being the person who utilizes the output in terms of end product or services. Non-value- adding is
everything done in the process which contributes no value for the customer but which they are forced to pay for
when they buy the product or service. In case of internal manufacturing point of view, there are three types of
operation that are to be serviced [4]. These can be distinguished are as follows: Non-Value Adding Necessary
but Non-Value Adding Value-Adding Non-Value adding operation is of total wasteful activity which never be
come to utilized in customer perspective and hence such operations are called as pure waste. It is necessary to
eliminate these non-value adding activities completely. These include activities such as Scrapping, Sorting,
Storing, Counting, Moving, Documentation etc. Necessary but Non-Value Adding operations may conclude to be
wasteful but these are necessary under the present work of activities. These may include walking larger distance
in order to receive parts or components, unpacking deliveries and transfer tooling form one position to another
position. A value adding operation involves those activities which makes the final product or service by the
processing of raw materials and with the help of manual labour; but in terms of customer perspective. These
include valuable activities such as Machining, Processing, Painting, Assembling etc.
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www.viva-technology.org/New/IJRI
VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9th National Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)
II. METHODOLOGY
The process analysis is carried out by acquiring the list of information from various enquiries with experts
in shop floor level, labourers and by directly participating in measuring time for various processes. The various
steps in the
VSM methodology are as follows.
Data Collection
Current State Mapping
Application of VSM Tools
Creating Future State Map
A. Data Collection
1) Customer Demand:
What is the product family?
How many products are required and when?
How many variety parts are made?
How many products are dispatched at a time?
How often are dispatches required?
What sort of packing is required?
How much amount of stock does the customer hold?
Other information like number of delivery points, delivery windows etc.
2) Information Flow:
What kind of forecast information is given by the customer?
What kind of call-off information is given by the customer?
Which department does this information go to in the firm?
How long does it stay there before being processed?
How do they pass it to as it moves towards suppliers?
What sort of forecast information given by suppliers?
What sort of call-off information given by suppliers?
What order quantities do supplier specify?
3) Physical Flow:
How many products are wanted and when?
How many different parts are required?
How many products are to be dispatched at a time?
How often do dispatches occur?
What sort packing is make?
How long does it take to dispatch?
B. Current State Mapping:
What kind of scheduling information is used?
What kinds of work instructions are produced?
Where is the information and instruction sent from and to?
What happens when there are problems in the physical flow?
C. Application of VSM Tools involves:
Table .1
Tools Parameters Tools Parameters
Process activity Process activity
mapping mapping
Identify lead time & productivity Identify lead time & productivity
opportunities opportunities
Demand amplification Demand amplification
mapping Volume with respect to Time mapping Volume with respect to Time
D. Creating Future State Map:
The improvement in the existing flow using various lean tools which will ultimately help in reducing
inventory, lead time, changeover time and improving productivity comes to this phase of work.
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www.viva-technology.org/New/IJRI
VIVA-Tech International Journal for Research and Innovation Volume 1, Issue 4 (2021)
ISSN(Online): 2581-7280
VIVA Institute of Technology
9th National Conference on Role of Engineers in Nation Building – 2021 (NCRENB-2021)
III. FIGURES AND TABLES
Each of VSM tools is not equally applicable to any of the wastes. These are based on the kind of wastes
and in which point of area we are applying at. The defining approximation weights are as shown in table 2
Table 2
Supply Physical
Process Production Quality Demand Decision
Chain Structure
Waste Activity Variety Filter Amplification Point
Response (Volume
Mapping Funnel Mapping Mapping Analysis
Matrix & Value)
Over Low Low Low
Production
Waiting High High Moderate
Transportation High Low
Over Low Low High High
Processing
Inventory Low
Motion Moderate Low High
Defects Low Low
IV. CONCLUSION
Value Stream Mapping works to be an effective tool in order to improve and gather the information at
each and every stations about station cycle time, uptime or utilization of resources, setup time, WIP inventory,
manpower requirement and the information flow from raw materials to finished goods.
REFERENCES
Journal Papers:
[1] Nitin Pandhi and Sanjeev Verma, “Value Stream Mapping in an Automotive Industry”, International Journal of Current Engineering and
Technology, ISSN 2277-4106, September 2012.
[2] R.M. Belokar, Vikas Kumar, Sandeep Singh Kharb, “An Application of Value Stream Mapping In Automotive Indu stry: A Case Study”,
International Journal of Innovative Technology and Exploring Engineering (IJITEE), Volume-1, Issue-2, July 2012.
[3] V. R. Murugananthan, K. Govindaraj, D.Sakthimurugan, “Process Planning Through Value Stream Mapping In Foundry”, International
Journal of Innovative Research in Science, Engineering and Technology, Volume 3, Special Issue 3, March 2014.
[4] Peter Hines, Nick Rich, “The seven Value Stream mapping Tools”, International Journal of Operations & Production Management, vol.17,
iss: 1 pp 46-64, 2013.
[5] Palak P. Sheth, Vivek A. Deshpande, Hiren R. Kardani, “VALUE STREAM MAPPING: A CASE STUDY OF AUTOMOTIVE
INDUSTRY”, International Journal of Research in Engineering and Technology, eISSN:2319-1163 pISSN:2321-7308.
[6] Pravin Saraswat, Manoj Kumar Sain, Deepak Kumar, July 2014, “A Review on Waste Reduction Through Value Stream Mapping
Analysis”, International Journal of Research, vol 1 issue 6, July 2014.
[7] Professor Peter Hines, David Taylor, “Going Lean”, January 2000.
[8] William M. Goriwondo, Samson Mhlanga, Alphonce Marecha, “Use of the value strem mapping tool for reduction in manufacturing. Case
study for bread manufacturing in Zimbabwe”, International conference on Industrial Engineering and Operations Management Kuala
Lumpur, Malaysia, January 2011.
[9] A. N. M. Karim, A. A. B. Jaafar, M. A. I. Abdullah, M. Haque, M. Y. Ali, S. A. Azline, “Applying Value Stream Mapping For Productivity
Improvement Of A Metal Stamping Industry”, Advanced Materials Research, October 2008.
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