Optimizing Manufacturing Performance by Minimizing Waste using Lean Practices

This project aims to reduce the wastages and the In today’s competitive industrial environment, companies are overall lead time in the manufacturing process for one of the crankshaft industries using Value Stream Map VSM and some other lean tools. It also aims to reduce the non-value-added activities in the manufacturing line to make the line more effective and to keep the production aligned. Here we have used Value Stream Map. First, the manufacturing line data was collected from the industry. Then current state map was drawn. By analyzing the current state map, non-value-added activities were identified which also includes some types of wastages. The wastes which we identified were the unnecessary motion of the component as well as the worker, inventory pile up and excessive scrap generation, rework onthe component. The leans tools were used to reduce these wastes. The tools which we used are Kaizen, Poka Yoke, and some other quality tools. A future state map was drawn with the new and improved processes. This ensures that the processes are more effective and efficient. The result of this project was excellent as we were able to increase the process ratio by 8.69%. Therefore, it is effective to use lean tools on the manufacturing processes in the industries. Key Words: Value Stream Mapping VSM, Lean Tools, Value Added Time, Non-Value-Added Time, Productivity and Wastages.