Lean implementation of value stream mapping for the reduction of production time and quality defect in electronic industry

Rosli, Syasya Syahindah (2022) Lean implementation of value stream mapping for the reduction of production time and quality defect in electronic industry. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Lean manufacturing is one of the techniques that many major businesses are trying to stay competitive in manufacturing industry and retain their position in the market. The increasing of production time leads to late delivery of products and causes of output demand cannot be met. The concept of lean manufacturing was developed for maximizing the resources utilization through minimization of waste and reduce the production time. In this report presents a study on the problems faced at the electronic production line that contribute to the high production lead time. Bottlenecks and work in progress are some of the problems found that cause an increase in production lead time due to non -value -adding activities. Thus, The aim of this report is to minimize the overall lead time in work process by finding out bottleneck and work in progress (WIP) using the Value Stream Mapping (VSM). Value Stream Mapping (VSM) is used as a suitable lean tool to identify the waste and non-value added activities by using time-frame formula through TAKT time calculation. Current State Map (CSM) is developed to list out all the information in current work process and identify the bottleneck problem by comparing the cycle time with TAKT time using Bar graph and Pareto chart. The identified bottleneck processes are classified into the type of production waste for analysis using a fishbone diagram to determine the three critical causes of the problems. Next, further analysing are made using the 5why analysis in order to determine the countermeasure using lean tool techniques approach for each problems. A Future State Map (FSM) is developed to design a new process flow through the elimination of root cause of waste and indicating the improvement proposal. Both current and future maps are analysed by comparing the result in terms of production lead times and cycle time to evaluate the overall gain achieved by using lean manufacturing techniques. As an expected result after discussing with manager production, it reduced lead time from 326 min to 166 min, which reduced by 50.8%.

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