Case Study On Value Stream Mapping

Lean production is an incorporated group of activities set up to attain high volume production by using low inventories of raw materials, processing goods, and finished goods (Chase, Jacobs, & Aquilano, 2006). Using a lean production process, the China plant will be able to produce goods at a lower cost. Riordan China plant will need to eliminate any waste in the production process to achieve the highest level of efficiency.

“Lean means creating more value for customers with less” (Krejewski, L., Ritzman, L.P., & Malhotra, M.K., 2013). Implementing this into a project can make the project very successful at a lower rate of cost and time. There are five steps in allowing the lean process to work successfully. This process is easy to remember but not always easy to achieve. Specifying the value from the customer’s point of view of the product that the customer is interested in purchasing is the first step. Identifying all the steps of value for the product the customer wants to purchase and eliminating the steps that are unnecessary is the second step. Creating a sequence of steps that flow in a consistent fashion and will flow smoothly toward the customer is the third step. Introducing the flow of the product that the customer is interested in purchasing and allowing the customer to pull value from the product is the fourth step. The fifth and final step in the lean technique process is “as value is specified, value streams are identified, wasted steps are removed, and flow and pull are introduced, begin the process again and continue it until a state of perfection is reached in which perfect value is created with no waste” (Lean Enterprises Institute, 2015).

Lean Manufacturing is actually a concept by way of the removal of all waste from any process associated with expense with the goal of a greater return by introducing additional products or processes that would be invested for a greater return on every dollar spent. For instance, how much more groceries can a family purchase if they could get paid for the right purchases made throughout the month, without sacrificing quality and usefulness.

The origins of lean thinking is actually created from the manufacturing industry. In the manufacturing or production industry, lean management design approach main objective is focusing on the elimination of waste and having a smooth workflow through a right process. Lean also enables the organization to improve performance.

Lean is defines the manufacturing philosophy that reduces the time between the shipping and customer demand, which based on the systematic method by eliminating waste, that means giving the customer what they want when they want it, and don 't waste whatever. Rahmana, Sharif and Esa (2013) suggested lean production is mentioned to improve the company 's performance from the philosophy in reducing waste in order. That means, lean system destination is the decrease cost by removing the non-value activities, which they are applying a category of tools and techniques for checking and eliminating defective in the production process. In the Evenort Company should emulate the five overriding principles of lean thinking in terms of implementing lean that there is guarantee the company has been driving correctly in the lean manufacturing (Cardiff 2015) as can show in table 1.

Mr Taichi Ohno first developed the Lean Concepts at Toyota ( Womack, 1998) The principles he developed are applicable both to the manufacturing and the service sectors( A.Lakshminarasimha,2005). To enable a proper perspective on the concepts of Lean, an attempt is made to briefly recapitulate on them.

The goal of research described application lean manufacturing to improving the manufacturing process on an assembly line in a car plant. Currently manufacturing process have so many disanvantagees,such as low efficiency, high cost, mass production quality is not stable, the accuracy is not high, and more labor and labor intensity,and these led to increased costs and less profit. Also sometimes the company cant achieve planned daily production target due to some activity wastes, which not added value to the production process.These are not conducive to the company’s future development. In order to make the company more competitive, company must have a new strategy to solve these problems. To achieve and sustain manufacturing excellence, you have to eliminate waste across your global production

Generally speaking, aims lean management to operate the most efficient and and effective organization as possible by having the least costs and zero waste. Thus, Lean should form part of a company wide strategy with the objective of decreasing its operating cost base and increasing market share (Wilson, 2010). Event though, Lean originates from manufacturing, the relevant principles are now increasingly being applied to the service sector (NIST, 2003).

The Lean methodology is a process management methodology that examines and enhance processes from the customer perspective. It looks to create proceedings that creates

And so they implemented Lean in 2004, in their repair division which reduced workplace. Lean manufacturing is applied to get rid of all non-value added steps of the procedure so that providing the best merchandise to clients. Lean was first invented by International Motor Vehicle Program but Taiichi Ohno had already implemented Lean in Toyota Production system. Ohno eliminated seven wastes such as overproduction, over processing, delay, inventories, defective parts, transportation and movements. Lean consists of many tools such as just-in-time, Kanban and etc.

The concept of lean production in a manufacturing organization basically means to try and maximise the use of materials to achieve optimum customer value and at the same time reducing waste and ensuring the same standard of quality in the finished product. Reducing the resources means it will cheaper for the organization to create the product plus also for the

Lean operations and supply chain originated from the Toyota Production System in Japan and have influenced manufacturing over the past two to three decades. Lean is described as the product of applying the Toyota Production System to all areas of an industrial process. Toyota’s strategies are based on Just in Time manufacturing, continuous flow, reducing lead times, eliminating non-value added waste, and excess inventory, a pull system centred on customer demand and continuous improvement (Liker, 2004). These integrated processes became the basis of Lean manufacturing and have recently extended to include all aspects of the supply chain process. Raw materials arrive Just in Time for production based on the demand of the

Department of Industrial Engineering, Sepuluh Nopember Institute of Technology, Kampus ITS Sukolilo, Surabaya 60111 Indonesia E-mail: pujawan@ie.its.ac.id

Lean is a process where creating more value to customers by minimizing wastage, time with less resources. Lean organization understand the customer value and try to increase proceed which adding more value to the business. In order to accomplish the lean thinking

The Lean Manufacturing approach is meant to transform non-value added activity into value added activity. Lean Manufacturing technology has its impetus and focus on whole operation. Lean Manufacturing methods are inclusive of all employees and involve a major change in the embedded attitudes of the individuals that make up the organizations. In today 's highly competitive world, the Indian organizations are striving hard to