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Fastener Industry VSM Case Study

This document describes a case study of value stream mapping conducted at Morning Star Industry, a fastener manufacturing company in Ludhiana, India. The company was facing problems like excess work-in-process inventory, issues with material handling and overproduction. Value stream mapping was used to map the current and future states. Data was collected from the shop floor and current state map showed gaps like overproduction and transportation waste. The future state map aimed to reduce lead time, inventory and processing time through techniques like just-in-time production and 5S. The value stream mapping resulted in reduced work-in-process inventory, processing time and operators while increasing production lead time.

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Saikat Ghosh
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436 views12 pages

Fastener Industry VSM Case Study

This document describes a case study of value stream mapping conducted at Morning Star Industry, a fastener manufacturing company in Ludhiana, India. The company was facing problems like excess work-in-process inventory, issues with material handling and overproduction. Value stream mapping was used to map the current and future states. Data was collected from the shop floor and current state map showed gaps like overproduction and transportation waste. The future state map aimed to reduce lead time, inventory and processing time through techniques like just-in-time production and 5S. The value stream mapping resulted in reduced work-in-process inventory, processing time and operators while increasing production lead time.

Uploaded by

Saikat Ghosh
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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CASES IN ENGINEERING

TOPIC-Value Stream Mapping: A Case Study of Fastener Industry


Morning star industry(fastener industry)
 Morning star industry was established in1973. an iso certified company 9001:2008
Certified firm engaged in manufacturing of High Tensile Automotive and Industrial
Fasteners. Located in Ludhiana.
 products: Bolt, Wheel Nut, Wheel Bolt, Stainless Steel, Hx Nut, Washer Low carbon high
tensile, Spring washer, Stud, Full stud.

 Problems faced by company


 there is no proper organization of what is stored where,
 Excess work in process inventory.
 problem regarding material handling.
 Overproduction in forming process.

 Technique Used: VSM ( Value Stream Mapping)


WHAT IS VALUE STREAM MAPPING?

 Includes all activities required to transform a product from raw material into the
finished goods.

 Visual representation map is drawn of every process .

 highlighting the opportunities for improvement that will impact production


system.

 A lean manufacturing tool to reduce lead time


Methodology
 Value Stream Mapping (VSM) is a pencil and paper tool that helps users see and
understand the flow of material and information as products make their way through the
value stream map.
 Select the product family
 Draw the current state map
 Draw the future state map
 Develop work plan for implementation future state.
 How to draw value stream map
 1. Obtained information from company

 2. Conducted time studies

 3. Data collected from shop floor observation.

 4. E-draw Max version 7.9.4 software is used to draw current and future state
VSMs.
DATA COLLECTED FROM M.S.I LUDHIANA

 Demand per month of Hex Bolt is 3500 pieces


 working days are 26 per month, shifts per day is 1 and the working hours per shift is
11hrs 10 minutes Available working time per day in minutes is 670.
 Takt time comes out to be 297 sec.
 then planning department send its requirement to different suppliers
 In present case MSI keeps raw material inventory of 15 days in their store
 Processes like cold forming, rolling, heat treatment, auto black, inspection and packing.
Details regarding inventory, avg. cycle time, lead time..
CURRENT STATE VALUE MAP
PROBLEMS IN CURRENT STATE MAP

 Acting upon the gap areas identified


 Overproduction is there at forming process. JUST IN TIME should flow between forming
and rolling.
 Heat treatment and auto black process which are performed outside the company and
transportation waste is there
 To reduce waste material should be moved to heat treatment process shift wise and
separate containers are used for different sizes of bolts.
 And 5S system is used at inspection and packing section by which the operation time and
less manpower will be required. As there is no proper organization of what is stored
where,.
Points followed by M.S.I for future state map

 Takt time: ratio of total working hours in one shaft to the total one shift demand
 Customer demand
 Process flow and material flow
 Information flow (manual and electrical)
 Calculate total product life cycle
 Identify opportunities for improvement and decide the daily target.
FUTURE STATE MAP
Results And Suggestions

 work in process inventory is reduced to 250pcs.


 Production lead time can be reduced to 16.85 days,
 processing time can be reduced to 280 seconds, operators could be optimum utilized to 16
 distance travelled by material can be reduced to 16006m.
Thank You

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