Lean waste analysis using value stream mapping for productivity improvement for C/MBR comp mid floor at PHN Industry Sdn Bhd

Raman, Pethal (2018) Lean waste analysis using value stream mapping for productivity improvement for C/MBR comp mid floor at PHN Industry Sdn Bhd. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

PHN Industry Sdn Bhd is one of the stable companies that produces automotive parts for car models like Civic, CRV, BRV and Accord. As high competition, there is an urgent need for manufacturing operations to continually strive to increase the productivity and output of their operations. The purpose of this study is to propose the Value Stream Mapping (VSM) at manufacturing company to reduce the processing time and production lead time caused it not complying with the amount of time available from customer demand for the work to be done. The VSM tool will lead researcher to define the current value state map and to analyse the waste and opportunities for improvement, and finally develop the future state map to propose to the company for C/MBR Comp Mid Floor product family. It has been concluded from the constructed current state map of C/MBR Comp Mid Floor value stream that the Future Value Stream Map (Initial Phase) suggests that a 33.1% processing time and 72.5% lead time reduction could be achieved, while Future Value Stream Map (Ideal Phase) suggests that a 53.9% of processing time and 99.8% lead time reduction could be achieved mainly through eliminating most of the waste that has been identified. The productivity improvement in term of labour-hour is 37.5% and 79.3% for Future Value Stream Map (Initial Phase) and Future Value Stream Map (Ideal Phase) respectively.

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