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Process Planning Through Value Stream Mapping In Foundry

V. R. Murugananthan , K. Govindaraj , D.Sakthimurugan

A value stream is all the actions (both value added and non-value added) required to bring a product through the main flows essential to every product for the production flow from raw materials into the arms of the customer and to design the flow from concept to launch as a lean manufacturing tool. Taking a value stream perspective means working on the big picture, not just individual processes and improving the whole not just optimizing the parts. In this paper, in a casting foundry with results are considered with current state maps and future state maps after following the different steps starting from the detailed time study for mapping the processes from raw materials to final product. When we engage in true process improvement, we seek to learn what causes things to happen in a process and to use this knowledge to reduce variation, remove activities that contribute no value to the product or service produced, and improve customer satisfaction. Process improvement means examine all of the factors affecting the process, the materials used in the process, the methods and machines used the transform the materials into a product or service, and the people who perform the work. Lean production starts from the arguments that adding value and reducing waste. Value stream mapping is different than conventional recording techniques, as it captures the information at individuals stations about station cycle time, uptime or utilization of resources, setup time, WIP inventory, manpower requirement and the information flow from raw materials to finished goods. This paper details the use of the value stream mapping in reducing waste in manufacturing company. With a case study in a one of the casting industry, the production process path is visualized by mapping the current state value stream map. After tracking the entire process, wastage affecting the cycle time are identified and its causes analyzed. A future state value stream map is developed and improvement ideas are suggested. Value stream mapping is proved as a useful technique to minimize the cycle time and increase the productivity.