Publication: Analysis of material and information flow using value stream mapping in manufacturing system
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Date
2023-07-13
Authors
Loo, Chin Hui
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Abstract
This paper presents the implementation of Value Stream Mapping (VSM) as an activity to visualize, record, and catalogue the production flow from customer demand back through raw material in the context of a chassis line manufacturing process. The primary objective is to identify process improvement opportunities using lean methods, specifically focusing on waste identification and elimination of non-value-added activities. By developing a current state VSM and analysing it, potential areas of improvement can be identified, leading to enhanced manufacturing performance indicators at the chassis line. Through an analysis of the current state map, the areas of waste in characterized by prolonged cycle time and excessive work-in-progress (WIP) inventory in the assembly process. By leveraging VSM, this case research pinpointed line balancing challenges associated with a substantial product family, consequently facilitating the
creation of a future state map. Subsequent implementation of measures to rectify the assembly line's balance yielded a noteworthy improvement, with the assembly line balancing rate increasing by an impressive 15.07%. However, the case research still found out that there is still room for improvement especially the Kanban raw material (RM) system in relation to the Chassis kitting process and the testing process, particularly the First Verification Test (FVT) process. To establish the improvement further, there are four proposed kaizen was suggested for future improvement.