Applying Value Stream Mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry

Abstract

Since its beginning, lean manufacturing has built a worldwide reputation based on results related to production improvement and cost reduction in several companies. This management philosophy focuses on customer value creation through the elimination of production wastes. Lean methods and techniques have spread their scope from the automotive industry to a wide range of industries and services. This article presents a case study that describes the use of the lean tool value stream mapping in the production process of automotive parts for a major automotive company. At the beginning of the project, relevant data from the process were collected and analysed. Subsequently, the initial process was mapped, the related wastes were identified, and then future processes were mapped and financial results were estimated. The proposals were presented on kaizen meetings, the action plan was discussed and the decision regarding which option to choose was taken. Consequently, the Cycle Time and the level of the workforce were reduced, the process was improved and savings were obtained.

Keywords:

•  lean manufacturing
• continuous improvement
• value-stream mapping
• automotive industry
• plastic injection

Disclosure statement

The authors state that they have no interests, financial or otherwise, which might be perceived as posing a conflict or bias.

Additional information

Funding

This work was supported by Portuguese funds through the CIDMA – Center for Research and Development in Mathematics and Applications, and the Portuguese Foundation for Science and Technology (‘FCT–Fundação para a Ciência e a Tecnologia’), within project UID/MAT/04106/2013.