Implementation of Value Stream mapping in a job shop for High – Mix, Low - Volume Environment
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In the present age of competitive manufacturing, every manufacturing industry wants to manufacture lean. One of the ways to achieve it is by eliminating inefficiencies in the operations. Value stream mapping is one of the vastly used tools to map value adding and non-value adding operations. However Value stream mapping cannot be used successfully on job shop in High mix-low volume production process because of variation in the cycle time. In this research, literature review on HMLV industries and its differences comparing it to mass production industries is shown. Value stream mapping as a tool and its applicable principles for future state mapping is given. By visual monitoring, current state map of the PSB shovel manufacturing was generated. Discussion with the production manager was carried out to map the future state based on the VSM principles. The current state mapping of the PSB shovel manufacturing showed the duration of every operation performed. While mapping the current value stream shortest cycle time was recorded. Every operation involved was analysed and bar graph was generated. Comparison between time operated, expected operation time, time stamp and lead time was made. Based on the following analysis and VSM principles Future state map was generated. The analysis shows the importance of monitoring in the job shop can lead to better future state of the production. Based on the results, it was clear that VSM tool could be used for monitoring and analysing the job shop in HMLV environment.