Abstract

Effects of Value Stream Mapping in a Processing Industry

Shakeel A. Shaikh; Muhammad Aqib; Hasnain Riaz; Umer Abdullah; Azmat Abbas; Usama Akbar

Abstract

Value stream mapping, a lean manufacturing tool, is widely used by industries to visually map the flow of production in order to highlight the opportunities for improvement. A study was carried out to identify non-value added activities using value stream mapping in a fast moving consumer goods industry “Colgate Palmolive (Pakistan) Ltd. Kotri plant”. Colgate is one of the leading manufacturers of consumer goods in Pakistan. Goods mainly include tooth paste, soup, and detergents. Initially, a current value stream map was developed for each process from receiving raw material to final dispatch. Time study was conducted using stopwatch along with observation sheet for collecting the data for each processes. The data was analysed statistically and steam leaf plots.  Non-value added activities (which included higher inventory, waiting time, over production and excess motion) were identified , which were highlighted on the future state value stream map and then finally ideal state value stream map was developed that resulted in reduction of lead time while eliminating the non-value added activities. It could be concluded that value stream mapping can be effectively used in processing industry to identify non-value added activities and to reduce lead time.

Keywords:  Value Stream mapping, inventory, lead time