Department of Leather Engineering, Khulna University of Engineering & Technology Khulna-9203

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APPLICATION OF VALUE

STREAM MAPPING IN A SWING


Md. Rasin Zaman , Ahamedul Kabir Hira , Md. Elias Uddin*
LINE FOR MAKING SHOE UPPER
Department of Leather Engineering, TO IMPROVE THE OVERALL
Khulna University of Engineering & Technology Khulna-9203
Corresponding to Dr. Md. Elias Uddin ([email protected]) EQUIPMENT EFFECTIVENESS

This case study is based on applying Value Stream Mapping(VSM) in a


Abstract

sewing line for developing shoe upper of Royal Footwear Industry Ltd, to To survive in the competitive condition, organizations have been attempting to
design and analyze current state map, process stream, to improve Overall
adopt world-class manufacturing throughout the previous decades. To
Equipment Effectiveness (OEE) and other performance parameters. Two new
accomplish this it is important to satisfy the competitive dimensions, for
maps have been designed and among them new map-one displayed the most
example, cheap product, good quality products, high delivery speed, and so on
encouraging result and has been chosen as the proposed map. Production
(Hines et al. 1998)

Introduction
lead time, inventory and processing time are envisioned in the future state
VSM, dependent on the proposed map. At last, OEE improved from 63% to
All these dimensions were observed at the ROYAL FOOTWEAR INDUSTRY
75%.
LTD and an absence of them was found in activities and processes. This lack of
competitive dimensions brings over costs, lower accessibility, and lower
Objective

• To analyze current status and report through VSM (Current state).


efficiency. Presently lean manufacturing is a very well-known term in numerous

• To identify and propose effective ways for improving current state


organizations in Bangladesh. Lean has numerous tools and theories and the
reasonableness of their application relies upon the particular operations and/or
VSM.
• To design the future state VSM and make sure that improvement is
processes performed by the organizations.

reflected in OEE. Value Stream Mapping (VSM) is a lean manufacturing tool to design and
analyze production process with required information where value adding and
non-value-adding works are identified and defined for process improvement
and waste minimization.

• Draw the current state map.


Methodology

• Identify where the improvements can be done to eliminate waste


.
• Develop future state map.
• Calculate OEE.
Process Flow
Total 36 processes are needed for the LIDL Bolly-19113-grey to be completed in the sewing line.
Total 4 input parts are given in the sewing line.
The input parts are Upper, Tongue, Collar lining, Counter.
Different operations are performed on the input parts and combined with one another.
Finally four main parts (Upper, Tongue, Collar lining, Counter) are assembled.

Figure 01: Current layout of the Figure 02: Current state VSM Figure 03: New layout 1 Figure 04: Future state VSM Figure 04: New layout 2
sewing line

COMPARISON OF LABOR PRODUCTIVITY COMPARISON OF OEE COMPARISON OF MANPOWER UTILIZATION COMPARISON OF EFFICIENCY
Current Layout New Layout 1 New Layout 2 Current Layout New Layout 1 New Layout 2
Current Layout New Layout 1 New Layout 2 Current Layout New Layout 1 New Layout 2

20
18 64.66% 59.08%
75%
16
55.67%
69%
62.88%

63% 61.55% 49.83%

Labor Productivity (Pairs/Shift) OEE Manpower Utilization Efficiency

Chase, R., Jacobs, R., and Aquilano, N. (2006).


 Achieving leanness is the goal of every manufacturing organization now a days. Successfully
Conclusion

Operations management for competitive advantage.


Reference

implementation of lean depends on understanding of existing problems and identifying where and how to New York. McGrawHill Irwin.
focus.
 In this research, value stream mapping is used to visualize the current state and identify the problems in Rother M, Shook J (1999) Learning to see: value
the sewing line. Future state VSM is drawn showing the improved status. stream mapping to add value and eliminate MUDA.
The Lean Enterprise Institute, Brookline, MA
 The proposed scenario offers 13.91% reduction in transportation time, 12.72% reduction in average cycle
time and 15.94% reduction in production lead time. In addition to 13.74% improvement in availability ,1% Garg D, Desmukh SG (1999) JIT purchasing: literature
improvement in performance and 12% improvement in OEE. review and implications for Indian industry. Prod Plan
 To achieve this improvement, the proposed layout must be implemented successfully. Control 10(3):276–285

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