FEASIBILITY AND IMPLEMENTATION OF VSM (VALUE STRAM MAPPING ) AND 5S IN CASTING INDUSTRY

MECHANICAL ENGINEERING

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 and 5s is used in casting manufacturing industry by focusing both on processes and their cycle times for a product valve body. 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 finishing , closing, molding 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 molding, closing, finishing cycle time and reduce rejected valve and non value activities.

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