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

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  • António Pedro Lacerda
  • Ana Raquel Xambre
  • Helena Maria Alvelos

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.

Suggested Citation

  • António Pedro Lacerda & Ana Raquel Xambre & Helena Maria Alvelos, 2016. "Applying Value Stream Mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry," International Journal of Production Research, Taylor & Francis Journals, vol. 54(6), pages 1708-1720, March.
    • Handle: RePEc:taf:tprsxx:v:54:y:2016:i:6:p:1708-1720
    DOI: 10.1080/00207543.2015.1055349
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    Cited by:

    1. Varun Tripathi & Somnath Chattopadhyaya & Alok Bhadauria & Shubham Sharma & Changhe Li & Danil Yurievich Pimenov & Khaled Giasin & Sunpreet Singh & Girish Dutt Gautam, 2021. "An Agile System to Enhance Productivity through a Modified Value Stream Mapping Approach in Industry 4.0: A Novel Approach," Sustainability, MDPI, vol. 13(21), pages 1-31, October.
    2. Wen, Xuanhao & Cao, Huajun & Hon, Bernard & Chen, Erheng & Li, Hongcheng, 2021. "Energy value mapping: A novel lean method to integrate energy efficiency into production management," Energy, Elsevier, vol. 217(C).
    3. Mariusz Salwin & Ilona Jacyna-Gołda & Michał Bańka & Dari Varanchuk & Anna Gavina, 2021. "Using Value Stream Mapping to Eliminate Waste: A Case Study of a Steel Pipe Manufacturer," Energies, MDPI, vol. 14(12), pages 1-19, June.
    4. Stadnicka, Dorota & Litwin, Paweł, 2019. "Value stream mapping and system dynamics integration for manufacturing line modelling and analysis," International Journal of Production Economics, Elsevier, vol. 208(C), pages 400-411.
    5. Ashwani Kumar Dhingra & Sunil Kumar & Bhim Singh, 2019. "Cost reduction and quality improvement through Lean-Kaizen concept using value stream map in Indian manufacturing firms," International Journal of System Assurance Engineering and Management, Springer;The Society for Reliability, Engineering Quality and Operations Management (SREQOM),India, and Division of Operation and Maintenance, Lulea University of Technology, Sweden, vol. 10(4), pages 792-800, August.

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