Aligning Value Stream Mapping (VSM) with Real-time Data for Manufacturing Excellence in Automotive Industry
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This case study delves into the journey of a diversified industrial group's Automotive Technology business unit, a global player in producing high-tech components for the automotive and machinery sectors. Focused on elevating its operational prowess, the company embarked on a mission to align Value Stream Mapping (VSM) with real-time data, creating an innovative approach to manufacturing optimization.
Key Points
- 13 products VSM made by team with real time data with date wise bifurcation.
- Interactive signs and data legends for data executed in VSM’s.
- Introducing MACRO’s in VSM for effective data fetching.
Client's Challenge
- Determination of flow of products being manufactured.
- Reducing lead time by referring the VSM’s.
- Refining and finetuning of existing VSM’s and making it more durable with respect to new database.
- WIP optimization and ease of calculating WIP.
PMI's Approach
The study was organized in a 3-stage process:
- Data Collection – Downloading data received from client over the internet server.
- Estimation & Data Analysis – Understanding the existing VSM’s available and layouts. Revamping the existing VSM’s and making it more useable with new data available.
- (Software used for VSM preparation is Microsoft Visio).
- Results and Conclusion – Dashboards for future planning, fatigue reduction, improved productivity, improved manpower utilization, identification of NVA work content.
Involvement of Associates –
- PMI – 2 Engineers.w
- Client – 1 Project Co-ordinator.
Data Collection:
- Receiving data from client.
- Interaction with client to understand process from existing data.
Data Analysis:
- Preparation of updated VSM’s as required by client.
- Removing absolute signs and information from VSM’s and adding new interactive information in VSM’s.
- Date wise building of VSM by pulling the data from database with the help of MACROS for fetching the output data as per date and demand.
Results & Conclusion
After doing analysis and evaluation following results were obtained –
- Improved VSM’s are made with real time data.
- New VSM’s with new sign and data.
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