Introduction In the world of globalization, manufacturing industrieshave become a more and more competing market, the businesses attempt toincrease their efficiency of operation so as to accomplish goal of satisfyingcustomers with price, quality, quantity and the shortest time of producing(Rasi,2014). As a result of increasing cost of labor in many manufacturing countriesand regulating operating cost, most of the companies might be a few reasonbusinesses which give rise to using outsource business of operation(Chowdhury,2017).
Lean manufacturing is one of main method which supportreducing cost of manufacture and waste of operation such as defective goodslong lead times and many process of production. Whenever, a waste occurs inproceeding, a value stream mapping (VSM) is built. The VSM is drawn in orderthat enterprises are aware of some defection point.
Evenort company is stainless steel industrial. The enterprise manufacturesa plenty of product and service including steel and alloy flanges, barprocessing, advanced manufacturing, deep water shipment and plasma cutting.Nevertheless, in case study focuses on some material which desire to produceflanges. Finally, the aim of investigation in lean manufacturing is morevalue-adding activities by dispatching the number of wastes in operation cycleby using lean operation and six sigma. Part1:Review the literature within industry Lean and 6s and strategiesimplementation Lean operation was firstappeared in The Machine the Changed the world book (Womack et al,1990).It was invented by Toyota company. The follow-on publication, Lean Thinking:Banish Waste and Created Wealth in Your Organization (Womack andJones,2003) describes lean principles and lean production. Lean word implies solution eliminating waste and non-valueadding activities and enhancing the value-added process.
Lean Manufacturing provides high quality product with low cost byeliminating waste in construction process (Maskell,2001). A value streammapping supports a waste identification of industry in order to improve theoperational performance (Kalsaas,2002). Value stream mapping (VSM) is effectivetool reducing time and inventory pipeline. Additionally, the identifyingvalue-adding and non-value adding activities is indicated by VSM. All materialmovement within plant between coming materials from suppliers to inventory andfinished products (finished goods) to customer is determined.
These areanalyzed and classified any activity both downstream and upstream in order thatprogress efficient operations. The analysis scheme has focus on seven levels asfollows: system, object, operation, activity, resource, application andcharacteristic (Jasti,2014). Therefore, VSM tool enhances simulation onproduction line whole supply chain in metal industries. VSM applicationdecreases their inventory and increase the productivity of the organization(Lamming,2000).
This report attempts to classify and remove waste in stainless steelindustry using VSM. Drawing current flow of VSM attributes to investigateframework development by utilizing both supply chain response matrix andprocess activities mapping tools. The main purpose of facilitator depicts requiredinformation and provide instruction about how direction of manufacturing lineis determined.
The operation division of the steel industry in this case studyfocuses on machines and movement of workers. Current situationate A creating value stream mapping is to gather data which reflects existentstatus in the operation flow. The assembling orders are received demandingcustomer on a monthly basis. The sales department obtains order from customer.
In addition, the information from sales department is transformed to beproduction planning control. To sum up, the department of production planningcontrol will handle procedure how manipulate product line without Muda (waste).All of the movements in the production line were identified in fivecategories including operation, transport, delay, inspectionand inventory.
The investigation has classified five processes and activitiesin machining production line as saw, turning, drilling, inspection and marking.The process flow chart of the currency state is one of the seven VSM tools. Theinformation of mapping is identified the critical operation and managing withtrouble procedure. Figure 1 shows current process in term of flow chart. Thecurrent map is also profitable identification existing problem each of the workstation in manufacturing process. Figure1.
Process flow chart of current state Analysis of thecurrent state of map To improve process and eliminate waste is applied by Kaizen activities andother lean manufacturing tools. The consideration has classified fiveoperational activities in current mapping. This investigation attempts to findout the waste and trouble in manufacturing process. The reducing number of workin process (WIP) gives rise to decline in defects, the cost of processingstorage, amount of stock and limitation of setup time. One of the significantobservation of this investigation is the movement of good in the productionline.
The study identifies a plenty of unnecessary movement of material andtransportation between saw machine and marking automobile. To illustrate, byusing pallet instead of single piece flow and continuous line, the product isflowing in term of batches. This case has provided a few more detection pointsin production line instead of performed checkup out of stream line. Moreover,an inventory level in manufacturing process should produce small batch sizes inorder to reduce inventory cost and improve quality of material as well. The observation of unnecessary movement and transportationcan identify being seven lean manufacturing wastes as follows: (1) Overcapacity (overproduction)(2) Unavailability of steel and alloy flanges(waiting)(3) Transportation of raw material and finished good (transportation)(4) Use of automated expeller manufactory (Inappropriateprocessing method)(5) Flange inventory (unnecessary plant)(6) Unnecessary movement (unnecessary motion)(7) Defective scrap (defects) Overcapacity is caused by non-expectation about customer demand planning.It is indisputable that excessive manufacture gives rise to a large ofdrawbacks.
Consequently, Lean manufacturing (LM) and just in time (JIT) are thekey to remove this waste. Policy of the enterprise should adjust following bypull demand or pull supply chain strategy. Unavailable of steel and alloy flanges are the effect of importing forgeflanges from overseas such as India and China. The waiting for six weeks bringsabout alternative decision-making plan and process.
The corporation might seeksupplementary suppliers outside countries or domestics in order to reducing timeof waiting. This can help to decrease the amount of inventory. Transportation of raw material and finished good