Improvement in Productivity of Leaf Spring Manufacturing Through Value Stream Mapping: A Case Study

Value stream mapping is a tool that includes all the phases of production line which is used to transform the raw material or unfinished goods into the desired finished product. A value stream observed all the activities through which the material gets transformed into the product. Value stream mapping use to provide the visual representation of every process that is related to existing material and information flow. A current state map of value stream helps us to identify the areas of waste and pinned them to improve, all the activity those are non value adding are also scrutinize by value stream. By making the modification in current material and information flow of existing plant a Future state map to be drawn. This map represents the improvement in selected family of product that is scrutinized in current state. In todays competitive era it is essential to every company that follow a path which derived the organization to forward than others. This will only make by the reducing the lead time, product cost, reducing non value added activities in plant these factor affect the overall production most significantly. The value stream mapping is tools that pay the attention to above cited factors. In this paper we opt the value stream mapping technique to eliminate the wastages, subjected to different process in leaf spring manufacturing plant. A CSM (current state map) represents the existing methods of doing and opportunities of improvement. Future state map represent the modification in process and overall reduction in production cost. Cost of leaf production decrease from 96.5lac to 96.1lac.