Redesigning of Production Line from Lean Manufacturing Tools by using VSM for a Screw Manufacturing Firm

Subbarao Chamarthi, Freedon Daniel, Harshit Sharma

Lean manufacturing tools, VSM, LR, DtD, Milkrun process, Karban cards.

Industries in the present time are competing with each other in order to increase, productivity, profits, and business. Lean manufacturing tools are beneficial for a manufacturing industry, as these can increase leanliness in respective industry. This research paper presents a case study of a screw manufacturing firm located in north region of India (Sahibabad). The basic purpose of this research paper is to conclude the effect of redesigning manufacturing line of respective screw manufacturing firm; two improvements are taken into account based on lean manufacturing. First, improvement is using kanban cards for storage of different type of screw, secondly, improvement through milkrun process. This case study illustrates VSM use, as well as kanban and milkrun systems application on an assembly line. The result of 3 different months is considered. Finally, the results obtained show the path of improvement, measured through the lean rate (LR) and dock-to-dock time (DtD).