International Journal of Innovative Technology and Exploring Engineering (IJITEE)

ISSN: 2278!"7#$ %olu&e'$ I((ue2$ July 2"'2

'#2

Abstract) Studies on applications of lean in a continuous
process industry are limited. There is lot of opportunities for
improvement in the process industries like automobile industry if
lean tools are utilized. This paper addresses the application of
Value Stream Mapping as one of the Lean tools to eliminate
waste and improved operational procedures and productivity.
!urrent state map is prepared and analyzed and suggested to
improve the operational process. Accordingly the future state map
is drawn. The study reveals that there is an improvement in the
takt time by implementing the proposed changes if incorporated in
the future state map.

"nde# Terms)!urrent state map future state map takt time
Value Stream Mapping $VSM%
I. INTRODUCTION
Before giving the definition of VSM it is important to
understand what Vaue and Vaue Stream is. !o"us on vaue
in the "onte#t of what the "ustomer$end%user is prepared to
pa& for. To "arr& out this a"tivit& the "ompan& needs to
understand what the "ustomer re'uires in terms of features
and performan"e( and how mu"h the& are wiing to pa& for
the produ"t. The out"ome of this a"tivit& is a "ear
understanding of what produ"ts the "ustomer re'uires. These
re'uirements ma& not )e feasi)e immediate&( )ut it provides
a true representation of "ustomer need.
The vaue stream is the entire "reation pro"ess for a
produ"t. The vaue stream starts at "on"ept and ends at
deiver& to the "ustomer. *ver& stage the produ"t goes
through shoud add vaue to the produ"t( )ut often this is not
the "ase. Mapping of the vaue stream aids the identifi"ation
of vaue adding and non%vaue adding +i.e. waste, a"tivities-
some e#ampes are isted )eow.
%alue adding activitie(
Ma"hining( .ro"essing( .ainting( /ssem)ing
Non value adding activitie(
S"rapping( Sorting( Storing( Counting( Moving(
Do"umentation et".
/ vaue stream map is an end%to%end "oe"tion of
pro"esses$a"tivities that "reates vaue for the "ustomer. /
vaue stream usua& in"udes peope( toos and te"hnoogies(
ph&si"a fa"iities( "ommuni"ation "hannes and poi"ies and
pro"edures. / vaue stream is a the a"tions +)oth vaue
added and non%vaue added, "urrent& re'uired to )ring a
produ"t through the main fows essentia to ever& produ"t0 +a,
the produ"tion fow from raw materia into the hands of the

*anu(cript received on July$ 2"'2.
+r, -,*, .elo/ar( produ"tion *ngineering department( ..*.C
Universit& of Te"hnoog&( Chandigarh( India
%i/a( 0u&ar( produ"tion *ngineering department( ..*.C Universit& of
Te"hnoog&(Chandigarh(India.
Sandeep Singh 0har1( produ"tion *ngineering department( ..*.C
Universit& of Te"hnoog&(Chandigarh(India.

"ustomer( and +), the design fow from "on"ept to aun"h.
Standard terminoog&( s&m)os( and improvement methods
aows VSM to )e used as a "ommuni"ation too for )oth
interna "ommuni"ation and sharing te"hni'ues and resuts
with the arger ean "ommunit&.
VSM is the pro"ess of visua& mapping the fow of
information and materia as the& are preparing a future state
map with )etter methods and performan"e. It heps to
visuai1e the station "&"e times( inventor& at ea"h stage(
manpower and information fow a"ross the supp& "hain.
VSM ena)es a "ompan& to 2see3 the entire pro"ess in )oth its
"urrent and desired future state( whi"h deveop the road map
that prioriti1es the pro4e"ts or tas5s to )ridge the gap )etween
the "urrent state and the future state.
The vaue stream mapping is used to ana&1e 6 map in
order to redu"e the waste in pro"esses( ena)e fow( and to
ma5e the pro"ess for )etter effi"ien"&. The purpose of vaue
stream mapping is to highight sour"es of waste and eiminate
them )& impementing the future%state vaue stream that "an
)e"ome a reait&. The goa is to )uid a "hain of produ"tion
where the individua pro"esses are in5ed to their "ustomer+s,
either )& "ontinuous fow or pu( and ea"h pro"ess gets as
"ose as possi)e to produ"ing on& what its "ustomer+s, need
when the& need it.
II. 7IT*R/TUR* R*VI*8
Ba5ema and Rotterdam +9::;, have "reated "urrent state
map for a stee produ"er( a stee servi"e "enter and first%tier
"omponent suppier. The "urrent state map identifies huge
pied of inventor& and ong ead%time. In the future state map
target areas were su)4e"ted to different ean toos in"uding
5an)an( supermar5et( and "ontinuous fow.
Baard and <owe +=>>;, suggest that( the vaue stream
mapping "an serve as a good starting point for an& enterprise
that wants to )e ean. It provides a "ommon anguage for
ta5ing a)out manufa"turing pro"ess. It ties together ean
"on"epts and te"hni'ues whi"h hep to avoid ?"herr& pi"5ing?.
It forms the )asis for an impementation pan )& heping to
design the whoe fow.
<apan and @ue"5mann +9::=, e#pain vaue stream
mapping in air"raft manufa"turing. The& draw "urrent and
future state maps were deveoped with the o)4e"tive of
redu"ing ead time a""ording to "ustomer re'uirements. The
impementation of the future state map attained ead%time
redu"tion.
Summer( =>>A has des"ri)ed /"tivit& Based Costing
+/BC,( identif& various "ost "omponents and ana&1e the
reative "ontri)ution to the tota "ost. The essen"e of /BC is
that( produ"t "onsumes a"tivit&( a"tivit& "onsumes resour"e
and resour"es generate "ost. Thus it is ne"essar& to deveop
the reationship )etween a"tivit&( "oast drivers and a"tivit&
measures. Target "osting is to anti"ipate the
/n /ppi"ation of Vaue Stream Mapping In
/utomotive Industr&0 / Case Stud&
-,*, .elo/ar$ %i/a( 0u&ar$ Sandeep Singh 0har1

2n 2pplication 3f %alue Strea& *apping In 2uto&otive Indu(try: 2 4a(e Study
'#!

a""epta)e mar5et pri"e through intensive "ustomer fo"us.
Design and manufa"turing team3s aies to )ring the produ"t
within the target "ost. Target "ost is the "ost that "an )e
in"urred whie sti earning the desired )enefit. The o)4e"tive
of the present wor5 is to demonstrate how a manufa"turing
s&stem operates with timing of step%)& step a"tivities.
Taii"hi Ohno +=>AA,( 8oma"5 et a +=>>:,( 8oma"5 and
Bones +=>>A( 9::C,( Danie. T. Bones +9::D,( Rother and
Shoo5 +=>>>,( and .eter <ines and Ni"5 Ri"h +=>>E, have
studied the impementation of Vaue Stream Mapping
effe"tive&.
Taii"hi Ohno +=>AA, "oud not see waste at a gan"e
+espe"ia& a"ross a geographi"a area,. <e deveoped
Materia and Information !ow Mapping +VSM, as a standard
method for mapping the fows visua& and it )e"ame the
standard )asis for designing improvements at To&ota % as a
"ommon anguage. It )e"ame one of their )usiness panning
toos. VSM is now utii1ed throughout the word( in man&
)usinesses to strategi"a& pan and it is the starting point to
an& ean transformation and impementation. The vaue
stream mapping was e#tended in the fied of air"raft
manufa"turing aso. /))ett and .a&ne +=>>>, have dis"ussed
the appi"ation of vaue stream mapping in an air"raft
manufa"turing unit. The& have deveoped the "urrent and
future state maps with the o)4e"tive of redu"ing ead time
a""ording to "ustomer3s re'uirements.
New +=>>F,( and Bones et.a +=>>E, and other resear"hers
deveoped individua toos to understand the vaue stream.
VSM e#tends guidan"e for improvements in the pro"ess(
identifies the need to improve wor5fow and fina& shows
avenues to redu"e waste.
Shingo +=>A>, has dis"ussed the strategies for the effe"tive
impementation of Vaue Stream Mapping in a wood industr&.
<e aso opines that oops "an )e formed to identif& the simiar
pro"esses and these oops wi )e hepfu in identif&ing the
non vaue a"tivities in a s&stemati" manner. <e has suggested
the wa&s to eiminate non vaue added a"tivit& and proposed
measures to in"rease the Vaue added ratio.
III. OBB*CTIV* O! R*S*/RC<
Toda&( automotive suppiers have a great "on"ern over
improving 'uait& and deiver& and de"reasing "ost( whi"h
eads to improved s&stem produ"tivit&. In order to remain
"ompetitive( waste from the vaue stream must )e identified
and eiminated so to run s&stem with ma#imum effi"ien"ies.
/ .rodu"tion is to order and arge num)ers of different
produ"ts are produ"ed( ea"h in reative& sma voume. /
.rodu"tion shop "onsists of num)er of ma"hine "entres( ea"h
with a fundamenta& different a"tivit&. The pro)ems of
ma"hine shop are dea&ed deiveries( ong 'ueues( and high
wor5 in pro"ess inventories( improper utii1ation. These
pro)ems in"rease overa "ost of produ"tion. The need for
"ustomi1ed produ"ts$parts with redu"ed ead times together
with the re'uirement of go)a "ompetitiveness re'uires that
produ"ts$parts )e produ"ed in sma )at"h si1es as per
"ustomerGs re'uirement. The pro"essing in sma )at"h si1es
ne"essitates the ad4ustment in the fow of produ"tion through
different pro"esses as per their pro"essing speeds. In addition
it re'uires "ose monitoring of pro"esses to redu"e pro"ess
varia)iit& +defe"t free produ"tion,( effi"ient panned
maintenan"e of a ma"hines +for in"reased avaia)iit&, and
redu"tion in non vaue added a"tivities su"h as setup times(
movement of materia in )etween the wor5 pro"esses and
additiona pro"essing of materia. The effi"ient utii1ation of
ma"hines whie produ"ing in sma )at"hes redu"ed 8I.
inventories( redu"ed throughput times and redu"tion in ead
times eads to "ompetitive manufa"turing. It is need for
ma"hine shop manufa"turing s&stem to adopt ean
environment.
To improve produ"tivit& )& identif&ing waste and then
removing that )& impementing ean prin"ipe in this industr&
we fo"us our attention on VSM too. Vaue Stream Mapping
ena)es a "ompan& to identif& and eiminate waste( there)&
streamining wor5 pro"esses( "utting ead times( redu"ing
"osts and in"reasing 'uait& and hen"e produ"tivit&. The goa
of VSM is to identif&( demonstrate and de"rease waste in the
pro"ess( highighting the opportunities for improvement that
wi most signifi"ant& impa"t the overa produ"tion s&stem.
In this stud& ean "on"epts are introdu"ed using VSM in
wor5ing environment.
I%, %S* *ET53+36378
To start improving produ"tivit& )& identif&ing waste and
then removing it )& impementing ean prin"ipe in the
industr& there is no other too )etter then VSM. The Vaue
Stream Mapping method +VSM, is a visuai1ation too
oriented to the To&ota version of 7ean Manufa"turing
+To&ota .rodu"tion S&stem,. It heps to understand and
streamine wor5 pro"esses using the toos and te"hni'ues of
7ean Manufa"turing. The goa of VSM is to identif&(
demonstrate and de"rease waste in the pro"ess. 8aste )eing
an& a"tivit& that does not add vaue to the fina produ"t( often
used to demonstrate and de"rease the amount of HwasteG in a
manufa"turing s&stem. VSM "an thus serve as a )ue print for
7ean Manufa"turing. This se"tion presents a methodoog& to
deveop a vaue stream mapping to identif& materia and
information of "urrent state.
Ienera& VSM has four ma4or steps as given )& Rother
and Shoo5 +=>>D,0
=. .rodu"t
9. Drawing "urrent state
F. Drawing future state
;. Deveop wor5 pan for impementation of future state.


V. C/S* STUDJ
/ "ase stud& was "arried out in an automo)ie industr&
C/./RO 7IMIT*D o"ated at Bawa +Rewari, in India. =C:
.rodu"ts are manufa"tured there. But main tunne foor was
"hoosen )e"ause it was most "riti"a
produ"t from the point of view of safet&
4urrent State +ra9ing
:roduct
;uture State +ra9ing
<or/ :lan

International Journal of Innovative Technology and Exploring Engineering (IJITEE)
ISSN: 2278!"7#$ %olu&e'$ I((ue2$ July 2"'2
'#=
purpose of the "ustomer. There is a ot of s"ope for stud& and
go for further improvement in the pro"ess to ena)e higher
produ"tion rate. <en"e this was see"ted for the "ase stud&.

Takt Time = Available time& customer demand
K 9E L=F9: LD:$C::::
K ;9.E se".
Num)er of shifts per da& K F(
Num)er of wor5ing da&s K 9E
Net wor5ing time per da& K =F9: min.
Demand for month K C::::
C&"e time K ;F se"
7ead time K A se"
.rodu"tion per da& K =F9:LD: $ +;FMA, K=CC: parts per da&
VI. R*SU7T
8hen "&"e time for ea"h pro"ess is "ompared with ta5t
time it is found that "&"e time of weding pro"ess e#"eeds the
ta5t time so there is need to improve the pro"ess "apa)iit& of
weding pro"ess to meet the demand of "ustomer within the
time.
So it "an )e improved )& using various ean toos )ut here
we are improving the "&"e time of weding pro"ess )&
introdu"ing a new weding ma"hine and )& improving a&out
of wed shop.
C&"e time )efore improvement K ;Fse".
C&"e time after improvement K 99 se".
N improvement in produ"tion K +9D:: O =CC:,$=CC:
There is near a)out DEN improvement )& improvement in
vaue adding a"tivities.
VII. CONC7USION
7ean produ"tion means "ontinuous improvement( we must
5eep on "hanging future state into "urrent state that wi not
end during our ife. VSM have )een proven to )e a great&
usefu too to eiminate some waste in a "&"e and find there
are more waste for &ou to eiminate in ne#t "&"e( during
whi"h ean )e"omes a ha)it or "uture.














































2n 2pplication 3f %alue Strea& *apping In 2uto&otive Indu(try: 2 4a(e Study
'##


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International Journal of Innovative Technology and Exploring Engineering (IJITEE)
ISSN: 2278!"7#$ %olu&e'$ I((ue2$ July 2"'2
'#>


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2n 2pplication 3f %alue Strea& *apping In 2uto&otive Indu(try: 2 4a(e Study
'#7

R*!*R*NC*S
P=Q O. Ram Mohan Rao =L( Dr. @ Ven5ata Su))aiah 9( Dr. @ Nara&ana
Rao F( T Srinivasa Rao - *nhan"ing .rodu"tivit& of hot meta in Bast
furna"e %/ "ase stud& in an Integrated Stee .ant- O. Ram Mohan Rao
et a. $ Internationa Bourna of *ngineering S"ien"e and Te"hnoog&
+IB*ST, ISSN 0
P9Q Mar"eo BR/I7I/R( Iionata C/RMIIN/NI ( !ran"es"o
S/MMORI Dipartimento di Ingegneria Me""ani"a( Nu"eare e dea
.rodu1ione( UniversitT di .isa( / N*8 V/7U* STR*/M M/..INI
/..RO/C< !OR COM.7*U .RODUCTION SJST*MS-
Internationa Bourna of .rodu"tion Resear"h.
PFQ S. .. Vendan L( @. Sa5thidhasan- Redu"tion of 8astages in Motor
Manufa"turing Industr&- Bordan Bourna of Me"hani"a and Industria
*ngineering .ages CE> % C>: Voume ;( Num)er C( Novem)er 9:=:
ISSN =>>C%DDDC.
P;Q D. Ra4enthira5umarL( ..V. Mohanram( S.I. <ari5arthi5( Department
of Mechanical Engineering,PSG College of Technology, Coimbatore;
.ro"ess C&"e *ffi"ien"& Improvement Through 7ean0 / Case Stud&-
Issue = +Bune 9:== Internationa Bourna of 7ean Thin5ing Voume 9(
PCQ Jang%<ua 7ian( <endri5 Van 7andeghem Department of Industria
Management Ihent Universit&- an appi"ation of simuation and vaue
stream mapping in ean manufa"turing- .ro"eedings =;th *uropean
Simuation S&mposium /. Ver)rae"5( 8. @rug( eds. +", SCS *urope
BVB/( 9::9. PEQ 7i#ia ChenS"hoo of *"onomi"s and Management(
Chang"hun Universit& of S"ien"e and Te"hnoog&- The /ppi"ation of
Vaue Stream Mapping Based 7ean .rodu"tion S&stem- Internationa
Bourna of Business and Management Vo. C( No. D- Bune 9:=:
PDQ 8iiam M. IoriwondoL( Samson Mhanga( /phon"e Mare"ha
Nationa
Universit& of S"ien"e and Te"hnoog Department of Industria and
Manufa"turing *ngineering- use of the vaue stream mapping too for
waste redu"tion in manufa"turing. "ase stud& for )read manufa"turing
in 1im)a)we- .ro"eedings of the 9:== Internationa Conferen"e on
Industria *ngineering and Operations Management @uaa 7umpur(
Maa&sia( Banuar& 99 O 9;( 9:==.
PEQ Stephen 7. 8oehre( Minnesota State Universit&( Man5ato 7oua&
/)ou%Shad&( Minnesota State Universit&( Man5ato- Using
D&nami" Vaue Stream Mapping and 7ean /""ounting Bo# S"ores to
Support 7ean Impementation- 9:=: */BR 6 *T7C Conferen"e
.ro"eedings Du)in( Ireand.
?8@ Bon <. Marve=- Chares R. Standridge9 =Iett&s)urg Coege +US/,-
9Irand Vae& State Universit& +US/,- / simuation%enhan"ed ean
design pro"ess- doi0=:.F>9D$4iem.9::>.v9n=.p>:%==F VV BI*M( 9::>
O 9+=,0 >:%==F O ISSN0 9:=F%:>CF.
P>Q Rother( M. 6 Shoo5( B. +=>>>,( ?7earning to See0 Vaue Stream
Mapping to /dd Vaue and *iminate Muda?( Broo5ine( M/0 7ean
*nterprise Institute +www.ean.org,.