Utilization of tool Value Stream Mapping (VSM) for Production... · Utilization of tool Value Stream Mapping (VSM) for ... should be free of weld spatter: ... company there is a reduction

Utilization of tool Value Stream Mapping (VSM) for improvement of welded assembly manufacturing process 15/07/2013 UNIJUÍ – RS - BRASIL PROF DR GILGUIMARAES

UNIJUÍ – RS - BRASIL Guimarães, Gil Eduardo

Doctor of Science in Materials Engineering Especialist in Industrial Engineering

Muller, Maiquel supervisor of productive cell of this study Student of Mechanical Engineering

Taffarel, Lucas Lash, Marcelo Bechert,Tobias

Students of Mechanical Engineering

15/07/2013 UNIJUÍ – RS - BRASIL 2

Introduction

Due to the globalization of markets and their consequent expansion, more and more companies seek to increase the efficiency of their processes.

Recently the philosophy of lean manufacturing has been consolidated in the industry, spreading the culture of waste elimination.


This systemic thinking focuses on value-creating processes, from raw material to finished product, involving all productive agents, from the most primitive supplier to the end customer.

In addition there is an extensive development of people and not only of processes and / or products.


The present work is an example of the actions that have been taken within the company in order to identify opportunities to improve processes and increase productivity.

These actions were motivated by customer requirements and by the action of competition


Value Stream Mapping (VSM)

The mapping process is a management tool that aims to help improve existing processes or deploy a new structure oriented to processes.

The mapping also helps the company to clearly see the strengths and weaknesses, as well as being a great way to improve understanding of the processes and increase business performance.


Ten steps to map and model a process Identify the process objectives Identify the process outputs Identify the customers of the process Identify the inputs and process components Identify the suppliers of the process Determine the boundaries of the process Document the current process Identify needed improvements of the process Consensus on the improvements to be applied to the

process Document the revised process


Current state map

Expedição

Corte Usinagem EstamparPosto de solda 1

Posto de solda 2

Acabamento Mandrilar Pintar Montar

OP A OP B OP C OP D OP D OP E OP F OP G OP H

PPCP

Cliente John Deere

ComercialComprasFornecedor

MP

E EE E EE EE E E

Produção em lotes


Current state map

Posto de solda 1

Posto de solda 2

Acabamento

OP D 100un OP D 100un OP E

EE E E

2:45:00 10:10:000:01:45 0:01:21 0:03:30


Current state lay-out


Analysis of the Current State MapActivities AV NAV

Posto de solda 1 0:01:45

Estoque 2:45:00

Posto de solda 2 0:01:21

Estoque 10:10:00

Acabamento 0:03:30

Subtotal 0:06:36 12:55:00

Total 13:01:36


Analysis of the Current State Map


Needed improvements of the process

Stock high on the work station of welding: All parts are stocked in the sector, which increases the need for physical space and makes it difficult inventory control.

Standby time high in welding and finishing; the production is done by batch, so parts needed to wait for the entire batch to be ready to proceed to the next process.


Disorganization of welding devices; the devices are arranged in a table, without identification and appropriate locations.

Layout of the work station of welding is inappropriate; the sector is not functional because the welder should get the parts at distances up to 3 meters, the input and output parts do not have a location set.


Suggested improvements 1st - Reduced inventory of components in gas welding:

All the inventory will be transferred to the warehouse, where there is an appropriate place in the industry and the quantity of welding parts in the work station will only be for the production of a day.

2nd - Develop continuous flow processes for welding and finishing: Create a cell welding and finishing that allows the continuous stream and eliminate stocks between processes.


3rd - Improvements in welding devices and welding processes: Restructure the layout, improve the arrangement of devices and use a anti-spatter spray of welding to decrease the time in the finishing operation.

4th - Definition of the areas in the assembly that should be free of weld spatter: Make a study of the areas where it really necessary to remove weld spatter for the finishing is made only where needed


Future state lay-out


Future state map

Expedição

Corte Usinagem EstamparCélula Pedais

Mandrilar Pintar Montar

OP A OP B OP C OP D,E,F OP G OP H OP I

Cliente John Deere

PPCP

ComprasFornecedor

MP

Comercial

E E EE EE E E

Produção Contínua


Future state map

Célula Pedais

OP D,E,F

E E

0:04:56



Activities Process TC (minutes) Operator %

1 Posto desolda 1 0:01:45 D 100

2 Posto de solda 2 0:01:21 E 100

3 Acabamento 0:01:50 F 100



Activities AV NAV

Célula Pedais 0:04:56

Subtotal 0:04:56 00:00:00

Total 0:04:56




CONCLUSÃO The future state map showed very significant

improvements, such as the elimination of non-value added activities.

It is evident, therefore, that with the application of value stream mapping (VSM) in the process of the company there is a reduction in lead time, more than 13 hours for about 5 minutes, giving the company much more quickness in meeting the demands of your client as well as a better use of its resources, which is crucial in a globalized world in which the company operates.


THANKS !!!

[email protected]


Utilization of tool Value Stream Mapping (VSM) for Production... · Utilization of tool Value Stream Mapping (VSM) for ... should be free of weld spatter: ... company there is a reduction

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