Reduction of Work in Process Inventory and Production Lead Time in a Bearing Industry Using Value Stream Mapping Tool

Abstract

Manufacturers always face cost-reduction and efficiency challenges in their operations. Industries require improvement in Production Lead Times, costs and customer service levels to survive. Because of this, companies have become more customers focused. The result is that companies have been putting in significant effort to improve their efficiency. In this paper Value Stream Mapping (VSM) tool is used in bearing manufacturing industry by focusing both on processes and their cycle times for a product UC- 208 INNER which is used in plumber block. In order to use the value stream mapping, relevant data has been collected and analyzed. After collecting the data customer need was identified. Current state map was draw by defining the resources and activities needed to manufacture, deliver the product. The study of current state map shows the areas for improvement and identifying the different types of wastes. From the current state map, it was noticeable that Annealing and CNC Machining processing have higher cycle time and work in process. The lean principles and techniques implemented or suggested and future state map was created and the total lead time was reduced from 7.3 days to 3.8 days. The WIP at each work station has also been reduced. The production lead time was reduced from 409 seconds to 344 seconds.