This Case Study deals with implementation of lean manufacturing techniques in crankshaft manufacturing system at an automotive manufacturing plant in South India. Lean Manufacturing was selected to meet the quality, cost and delivery targets. After Implementing lean manufacturing, manufacturing lead time reduced by 40%, defects were reduced, high process capability achieved, quick response to customer demands.

1. Application of Value Stream
Mapping for Reduction of
Cycle Time in a Machining
Process
Sumit Bhattacharya 851
Sathish Kumar 863

2. Abstract
• This Case Study deals with implementation of lean manufacturing
techniques in crankshaft manufacturing system at an automotive
manufacturing plant in South India.
• Lean Manufacturing was selected to meet the quality, cost and delivery
targets.
• After Implementing lean manufacturing, manufacturing lead time
reduced by 40%, defects were reduced, high process capability
achieved, quick response to customer demands.

3. Problems in existing system
• High Additional processing time
• More number of workers
• Consumes more resources
• More inventory
• More scrap
• High Cycle time

4. Earlier System Outline
• Earlier it was manufactured in
three different location
• Movement in zig-zag pattern
• Poor communication
• Unbalanced work content

5. New Outline after Implementation
• Zig-Zag flow eliminated
• Unidirectional
• Better communication
• Operator requirement less
• Well organized

6. Value Stream Mapping
• Method of lean manufacturing which uses symbols, metrics and
arrows to show and improve flow of inventory and information
required to produce a product or service.
• Value stream mapping allows one to determine where the waste
occurs.
• This helps in identifying various factors: Value added time, Non Value
added time, cycle time, changeover time.
• This helps in identifying and eliminating waste.

7. Current Value Stream Mapping State

8. Future State after implementation

9. • KAIZEN 1: Implement the Modified Process by eliminate and
combine operation.
• KAIZEN 2: Implement the modified process by optimizing the
process parameters.
• KAIZEN 3: Implement the modified process by tooling improvement
and introduce CNC lathe.

10. Results after Implementation
• Single piece flow for crankshaft manufacturing system was
established.
• The non- value adding activities were eliminated
• Quick response to customer demand to supply frequently in small lots
• Complete manufacturing was established to meet customer
requirements and quality.

12. Conclusion
• Implementation of Lean Manufacturing in crank shaft manufacturing
cell would eliminate the 8 non-value adding wastes like over
production, waiting, unnecessary transport movement, defects and
unused employee creativity.
• This would also improve the flexibility of the production process.

13. References
1. K. Venkataramana, B.Vijaya Ramnath, V.Muthu Kumar,
C.Elanchezhian, 2014 ‘Application of Value Stream Mapping for
Reduction of Cycle Time in a Machining Process’, 3rd International
Conference on Materials Processing and Characterisation.