IJSRD - International Journal for Scientific Research & Development| Vol.

4, Issue 02, 2016 | ISSN (online): 2321-0613

Application of Value Stream Mapping for Productivity Improvement-

Case Study of a Foundry Industry
Bhanu PS Tomar1 Avinash Nath Tiwari2
1
M.Tech Research Scholar 2Assistant Professor
1
Department of Production Engineering 2Department of Mechanical Engineering
1,2
Jagannath University, Jaipur, Rajasthan, India
Abstract— The term value stream mapping is defined as a price. To make this entire system correct VSM is the most
lean manufacturing tool which includes all the actions both common and helpful tool to make entire stream valuable and
value added and non-value added required bringing a to eliminate non-value adding activities. Value Stream
product into its finished state. In today’s global competitive Mapping (VSM) is a set of methods to visually display the
world, the era of mass production and pull system is over flow of materials and information. Whenever there is a
and companies are experiencing a heavy pressure because of product for a customer, there is a value stream and the
globalization. Main objective of any organisation become change lies in the seeing it. Value Stream map is also known
satisfying customer requirements. Value is now defined by as “Material and information flow mapping” in Toyota. It is
customer point of view as customer willing to pay and what developed by a work carried out by Taiichi Ohno at Toyota
worthiness that product has for them. They will not pay for in the 1960’s - 70‘s. VSM doesn’t require a tough and
any waste and companies have to be focused on this. Thus, tedious work. It requires just a paper, pencil tool to draw
companies need to implement Value Stream Mapping CVSM and FVSM and brainstorming sessions for
(VSM) because it has been established as one of the best and improvements and comments. In one project there are two
most convenient tools of lean manufacturing value stream maps. A current state map (CVSM) and a
implementation and to identify and eliminate all kind of future state map (FVSM). A current state value stream map
wastes. This paper presents a case study of application of shows what is the actual processing steps are at the
value stream mapping in an Indian foundry industry. This beginning of a project. It identifies wastes and NVAs. The
industry was manufacturing Crusher Jaw plates. The future state map shows what the process should look like at
application of these plates is in stone cutting plants. The the end of the project? And how these processes can be
case study has been used to show the applicability and improved? After these improvements as they are suggested
importance of VSM in foundry industry. Current state of the changes in current system are made. Now, This FVSM will
jaw plate manufacturing has been developed by using VSM be the CVSM for next project. And this cycle continuously
symbols. This current state map was then used to identify goes on. We can use VSM as a Lean method to identify the
areas for improvements. From the findings of CVSM it was opportunities of improvements for future. VSM method is
observed that lead time was quite high for given demand, associated with production as well as with service sectors. It
Cycle Time was more than Takt time and number of can be used for Reduction in lead and cycle time of various
operators could be reduced by combining operations. As a processes, Customer satisfaction and value addition,
result, including individual improvements in WIP, Labour Managing supply chain activities, Development of efficient
Utilisation, Cycle Time, Lead Time, Changeover Time, the production techniques, Improving productivity and
overall improvement was found near to 22%. profitability, Layout and equipment modification etc.
Key words: Lean Manufacturing (LM), VSM (Value stream This paper describes a case study explaining the
map), CVSM (Current state value stream map), FVSM successful implementation of VSM into a foundry industry.
(Future state value stream map), VA (Value added activity), The product being manufactured is crusher jaw plate. Lean
NVA (Non-value added activity), Kaizen, WIP, Lead Time manufacturing is a widely accepted and applied technique in
manufacturing industries and it has been cumulatively
I. INTRODUCTION implemented all over the world by many leading
To ensure competitiveness in this high pressured continuous organisations. Global competition among the industries is
changing and developing market conditions, implementation constantly arising and industries are facing very tough to
of lean manufacturing is become necessary for face changes. To sustain changes they need changes and
organisations. Lean manufacturing is identified as a improvements in their system. For this adoption of lean tool
comprehensive set of much effective techniques for waste is must. Lean Manufacturing is extensive and intelligent set
identification and its elimination from processes in order to of tools for waste identification and reduction or elimination
enhance system flexibility, effectiveness, efficiency and from manufacturing processes to make them more effective,
reduce overall production costs. One of the most common more flexible, and more efficient and reduce individual as
and convenient way to implement lean manufacturing is the well as overall costs of operations and product being
application of Value Stream Mapping (VSM). Before going manufactured. One of the most effective and convenient
to define VSM, we must understand what is value? Value of way to achieve all targets is the application of VSM on
the product is measured at end users (customers). Value of specified product family.
the product for customer is in terms of money, satisfaction, The VSM process is simple and straight forward. It
performance, service or elegance. To serve the best value to includes all the areas starting from raw material
the customers company needs a customer requirement data. procurement to the selling of final product into customer
This data become helpful to make a right product for right hands. Along with processes, it also includes customer
customer with right specification at right time with right

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 Application of Value Stream Mapping for Productivity Improvement-Case Study of a Foundry Industry
(IJSRD/Vol. 4/Issue 02/2016/364)

demand, service levels and work back by documentation of Applied VSM successfully at a
7. Rhonda R.Lummus
all the necessary data required to manufacture a product. physician clinic for quality
et.al.; 2006[10]
Crusher jaw plate is a complex product to be improvement
manufactured in a foundry industry, it consist of about Applied VSM successfully at
eleven major steps to be considered for study. The manufacture to order at small
operations starting from procurement of raw material to raw 8. Markus L. Stamm
and medium enterprise
material, melting mould and design making, core and et.al.; 2008
showing potential reduction in
pattern making, knocking, degating, grinding, fettling, lead time
quality inspection etc. the main aim of the industry was to Address various wastes in the
reduce overall cost, lead time and increment in value added 9. Seth et.al.; 2008[13] supply chain of the edible
activities up to an acceptable value in economical manner. cottonseed oil industry
VSM has been selected based on questionnaire, personal Explained how VSM helps to
meetings and discussing with managers and operators on bring the gap between current
floor. Production planning and control, sales and marketing, 10. Bhim singh and
state and future state map and
design and pattern shop has helped us to give past records S.K.sharma; 2009[14]
developed a road map to take
about demands production volume, daily working time etc. improvement areas.

II. LITERATURE REVIEW Applied VSM in Indian

context in man camshaft
The term value stream first used by Womack, Jones and 11. S.Vinod et.al.;
manufacturing industry to
Ross in their book “the machine that changed the world”[1]. 2010[15]
enable leanness in that
And later it was described thoroughly in “Lean thinking” by organisation
Womack and Jones[2]. Lean manufacturing uses tools like
Poka Yoke, Kaizen, Standardisation, workplace organisation Applied VSM to find out
and waste reduction, Inventory management etc. to reduce hidden reserves and to avoid
12. Duranik et.al.;
manufacturing wastes. VSM is an excellent tool for any bottlenecks
2011[21]
enterprise that wants to become lean. Rother and Shook An idea of zero percentage
(1999) defines VSM as powerful tool that not only waste was developed
highlights process inefficiencies, transactional and Deployed VSM along with
communication mismatches but also guides about the KANBAN focusing on
improvement. Jones and Womack explain VSM as the productivity improvement by
process of visually mapping the flow of information and considering a case study of
13. Ritesh bhat et.al.;
material as they are and preparing a future state map with gear pump manufacturing firm
2011
better methods and performance. Seth and Gupta have made in Indian context and findings
a successful attempt to use VSM as a technique to achieve were reduction in production
improvement in productivity at the supplier end for an lead time and number of
automotive industry[9]. Over the years many lean workers
manufacturing tools to support value stream have been Defined VSM in other words
developed and many more are being developed. The and defined that VSM
following table provides an overview of major contributions 14. Rahani AR et.al.; involves in all processing steps
in the field of VSM. 2012[24] to analyse NVA and VA as a
MAJOR visual tool to identify hidden
AREA OF WORK waste and source of waste
CONTRIBUTORS
Defined thoroughly value Implemented VSM for process
1. Womack and jones;
stream mapping in book” lean 15. R.M. Belokar et.al.;
capability improvement of
1996[2]
thinking” 2012[22]
welding process. significant
2. Hines (1999), Grewal Identification and elimination improvement was found as a
and Singh (2006) of Muda result
3. Brunt (2000) Applied VSM in SriLankan
;Abdulamek and Improved productivity of apparel industry with an
Rajgopal (2007); process industry 16. Silva et.al.; 2012[23] objective to find out
Seth et.al.; (2008)[13] applicability in apparel
Defined VSM as visual industry.
4. Tapping et.al.; representation of the material Applied lean manufacturing
2002[6] and information flow of a using VSM in an auto part
particular product family manufacturing cell.as a result a
17. Harwinder singh
Carried out VSM study in 9 major portion of cycle time,
et.al.; 2013[25]
5. Hugh L. Macmanus major US aerospace agency reduction in WIP and
et.al.; 2002 and correlated various factors reduction in production lean
based on collected data time for targeted process.
6. Seth and Gupta; Productivity improvement at
2005[9] supplier end

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 Application of Value Stream Mapping for Productivity Improvement-Case Study of a Foundry Industry
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Implemented LM using VSM contributing high value to L/T and WIP are identified. It was
as a tool in an auto component noticed that number workers could be reduced if operations
18. Naga Vamsi et.al.;
industry in India. Area of been combined and optimized. He major processes steps
2013
improvement in WIP, lead were design making patterns making which were adding
time, cycle time identified. high C/T to processing L/T.
VSM applied in crankshaft
manufacturing system at an IV. METHODOLOGY
19. K.Venkataraman automotive manufacturing The methodology for implementation of value stream
et.al.; 2014[29] plant. In south India. The mapping is essentially having five steps. These all steps are
objective of study was to to be performed in a sequential way. The sequence is as
improve export sales. follows
Case study was carried out in
an automotive industry in seat
20. Palak p.seth et.al.; making process. After
2014[28] implementation of NVA
reduced to a major value and
also WIP reduced.
Applied VSM in glide Fig. 1: VSM Methodology
manufacturing in Zimbabwe
21. Maxwell Dzanya A. Selection Of Critical Product Family
[30] with the aim of eliminating
et.al.; 2015
waste and improving quality in The first step is the selection of the product family from the
production. product mix for study. This critical product family should be
Carried out a case study based chosen after studying the product mix thoroughly. This
of VSM in Brass Lamp product family will be the ground for further study.
Manufacturing. A seven step
B. Drawing Current State Value Stream Map
22. K.P.Paranitharan; methodology was used to
2015[35] eliminate NVA and for Data regarding the customer demand and company
productivity improvement and production should be collected in this step and data
to study the impact of VSM on regarding processes and operations should be used to
industry. develop a current state map. This map will show the present
Applied VSM with integration scenario of the organisation. A wide range of the data
of KANBAN technique for related to supply and demand can be analysed by using
aiming to achieve high quality current state map.
23. S.R.vijaykumar et.al.;
products with maximizing C. Drawing Future State Value Stream Map
2015[38]
productivity for selected one
After thoroughly analysis of CVSM, future state map will be
part family among product
developed depicting the various modifications and
families.
improvements incorporated in current manufacturing
VSM methodology
processes. FVSM shows ways to improve a process. After
successfully applied to current
analysing the existing processes of an organisation, various
working processes, quality
proposals and suggestions for waste elimination and process
24. Satish Tyagi et.al.; improvement, sustainable
optimization can give a way to the organisation for future
2015[37] manufacturing.
improvements.
Applied VSM while product
development is being carried D. Work Plan
out in their initial phase. By using various lean tools, an organisation have to develop
Demonstrated application of and select best and optimized implantation plan in order to
VSM on real case study and achieve improvements in best acceptable ways. Some VSM
discussed its outcomes and to symbols are used in VSM drawing for easy and
25. Martin et.al.; 2015
show that by using VSM comprehensive understanding. Some basic symbols are
organisation can achieve long shown in fig 1.
and short term goals.
Table 1: Major Contribution in the field of VSM E. Implementation and Comparison
This step shows the implementation of various suggestions
III. PROBLEM DEFINITION made in FVSM. After implementation it becomes necessary
to compare the outcomes with existing data. This shows us
In this industry they were manufacturing Crusher Jaw plate.
that how effectively the improvements are made and what
Jaw plate is a very critical component in working of crusher
the possible benefits could be.
for stone cutting. This jaw plate manufacturing includes
various operations from melting, moulding, knockout and
degating, fettling, grinding etc. by applying VSM it was
found that lead time and WIP were too high and processes

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 Application of Value Stream Mapping for Productivity Improvement-Case Study of a Foundry Industry
(IJSRD/Vol. 4/Issue 02/2016/364)

Fig. 2: VSM Symbols

Current state map for the product crusher Jaw plate is
V. CURRENT STATE VSM depicted on next page.
The Current State Map also referred as Current Value All the necessary data collected for CVSM was
Stream Map (CVSM) gives us information about what is collected as per approach recommended by Rother and
currently going on in the organisation. it is a pictorial Shook (1999) with consulting managers, workers, shop floor
presentation of current data and information flow. Drawing supervisors and engineers. The first step towards
with specialised symbols of VSM, current state map development of CVSM is that the final product/ product
considers entire processes for targeted product or product family must be selected and sorted according to problem.
family. Starting from the raw material procurement it ends This research paper is focusing on manufacturing of crusher
with delivery of finished piece. Thus after developing jaw plate and the same product with associated
CVSM for a targeted process, it becomes very easy to find manufacturing operations is selected for analysis.
out the factors and processes which are contributing in NVA After time study of various operations in
and Waste production. It also gives indications to the areas manufacturing of the product the current state map
which can be improved. Thus after data collection it is the developed is as shown in figure-
very crucial step towards generation of future state map.

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 Application of Value Stream Mapping for Productivity Improvement-Case Study of a Foundry Industry
(IJSRD/Vol. 4/Issue 02/2016/364)

Fig. 3: Crusher Jaw Plate- Current State Value Stream Map

Quantitative Analysis of Current State Value Stream Map-
After analysing the current state map thoroughly following VI. FUTURE STATE MAP
data is found- The future state map is a visionary map drawn to propose
Total value added time = 4795.3 minutes suggestions and recommendations for an ideal value flow.
Total lead time to fulfil customer order = 7 days Several lean manufacturing techniques are adopted to reduce
For total available time in the plant value added time = lead time and increase throughput. With the aim of
4795.3 continuous improvement, this company is suggested several
7 days * 8 hours/day * 60 min/hour ways to reduce lead time, WIP, cut down the number of
= 1.42% operators and to increase value added time percentage in
Total number of operators(workers) working = 28 available plant time. The suggestions includes use of
Total WIP = 10.8 Tonne/day supermarket concept to provide local storage, aid from
Total change over time = 146.6 Minutes. external source, applying the concept of work cell,
The current state map was drawn with the help of combining operations,5S,FIFO concept etc. these
information collected within the firm. With the information suggestions not only helps the company to improve its
collected, a clear understanding of the entire manufacturing operation procedures but also opens new ways for future
process is depicted for the product Crusher Jaw plate. Now improvements.
areas associated with Non-Value added activities can be After analysing CVSM improvement areas are
traced and waste identified so that avenues for improvement identified using kaizen bursts which will lead to reduce
can be seen clearly and suggestions recommended WIP, L/T,C/T,C/O. a number of proposals are made to
accordingly for a leaner company. The next step after improve CVSM for this various modifications are done in
plotting CVSM is to identify non value added activities and the manufacturing processes of crusher jaw plate. To
to improve the processes by applying kaizen activities and synchronise Takt time with C/T modifications in
other lean tools. The CVSM is developed keeping in mind manufacturing steps are done i.e. combining
the concept of Lean manufacturing. A few assumptions were operations,5S,Pull,FIFO etc. which are clearly shown in
made. These assumptions are that the demand is stable, FVSM. Some activities should be eliminated which are not
machine utilization is 100% and shift timing is fixed. CVSM adding any value to the product. FVSM below shows areas
collects the information at the particular instance, so some that require improvements and ways in which they can be
variation in number of operators and production rate are not improved. After improvements lead time for the product
considered.

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 Application of Value Stream Mapping for Productivity Improvement-Case Study of a Foundry Industry
(IJSRD/Vol. 4/Issue 02/2016/364)

manufacturing comes to 4.9 days from 7 days. The C/T is also reduced from 4795.3 minutes to 4262.2 minutes.

Fig. 4: Future Value Stream Map

A. Calculations ability to produce in 7 days is 315+94.5=409.5 pieces (in 7
days). If we calculate for the whole month this amount is
%value added time improvement = (1.82-1.42)*100
equal to 1755 pieces.
= 28.16%
1.42 C. Comparison for Production in A Month
Reduction in WIP = (10.8 – 8.6)*100 = 20.37% Current state production- 1350 pieces
8.6 Future state production- 1755 pieces
Reduction in Lead Time = (7-4.9)*100 = 30% Increase in production- 405 pieces
4.9 % improvement in production- (405/1350)*100= 30%
Reduction in Cycle Time = (4795.3-4262.2) *100 =
11.12% D. Comparison for Productivity for A Month
4795.3 In Current In Future
Reduction in number of workers = (28-22) *100 = State(CVSM) State(FVSM)
21.43% Productivity 1350 pieces 1755 pieces
28 Table 2:
Reduction in changeover time = [(146.6-114.9)*100] / 146.6
= 21.62%
B. Improvement in Productivity
In current state the lead time was 7 days and after
improvements suggested it becomes 4.9 days and it shows
reduction in lead time by 2.1 days. This organisation
produces about 45 pieces daily, then total amount produced-
2.1*45=94.5
This shows that earlier this company was
producing 315 pieces in 7 days, now after improvements

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 Application of Value Stream Mapping for Productivity Improvement-Case Study of a Foundry Industry
(IJSRD/Vol. 4/Issue 02/2016/364)

Fig. 5: Improvement in Productivity

VII. RESULT AND DISCUSSION

Every industry aims to maximize its productivity, profit and Fig. 6: Comparison for Lead Time and Value Added Time
aims to minimize WIP,C/O,C/T,L/T, Waste and Rework etc.
the common requirements of all these goals are the huge
investment in capital and also proper tools to get these done.
This research work has been intended to VSM, which is
becoming an necessary tool for practising Lean
manufacturing in actual production scenario. The results are
shown in form of comparison between various process
parameters for CVSM and FVSM.
Value in
Process Value in %
Current
parameters Future state Improvement
state
% Value 1.82%
1.42% 28.16%
Added Time
WIP(T/D) 10.8 8.6 20.37%
Lead
7 4.9 30% Fig. 7:
Time(days)
Total Cycle 4795.3
4262.2 min 11.12%
Time min
No. of
28 22 21.43%
Workers
Change Over
146.6 min 114.9 min 21.62%
Time
Average
22.12%
Improvement
Table 2: Comparison Between CVSM And FVSM

Fig. 8:

Fig. 6:

Fig. 7: Comparison For Wip, Labour And Changeover Time

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 Application of Value Stream Mapping for Productivity Improvement-Case Study of a Foundry Industry
(IJSRD/Vol. 4/Issue 02/2016/364)

VIII. CONCLUSION Indian case study of a manufacturing firm” Emerald

It is proven beyond doubt that VSM is a powerful tool for Group publishing limited ISSN 1368-3047 Vol.13 No.3
lean manufacturing and allows firms to understand and [16] Vinodh S.,Arvind,K.R. and Somanathan M.(2010)
continuously improve its understanding towards lean. The “Application of Value Stream Mapping in an Indian
present work provides a case study of improvement in camshaft manufacturing organisation” Journal of
productivity in a foundry industry by the application of Manufacturing Technology Management Volume
VSM in the manufacturing of Crusher Jaw Plate. It focuses 21,No.7,pp. 888-900.
on the revamp of the operations by eliminating non value [17] Bhim Singh, Suresh K. Garg, and Surrender K. Sharma
added activities and improving cycle efficiency through (2011) “Value stream mapping: literature review and
VSM. This paper compared the current state and future state implications for Indian industry” International Journal
of a manufacturing firm and witnessed 28.16% Advanced Manufacturing Technology 53 pp. 799–809
improvement in value added time, 30% reduction in lead [18] K. P. Paranitharan, M. ShabeenaBegam, S.
time, 11.12% reduction in cycle time. On an average the SyathAbuthakeer, M. V. Subha (2011)“Redesigning an
overall improvement was found near to 22.12%. Automotive Assembly Line through Lean Strategy”
International Journal of Lean Thinking Volume 2, Issue
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