“Value Stream Mapping for wiring harness”

A Synopsis of Final Year B. Tech Under Industry Internship & Project Track to Be Submitted to
Rajarambapu Institute of Technology, Rajaramnagar.

FOR THE DEGREE OF

B.Tech.
In
Mechanical Engineering

Under Industry Internship & Project (IIP) Track

(Project at Elcom Internationals Pvt. Ltd., Kolhapur)

BY
Ms. Karpe Vijaya Sudhir
Roll no.1656009
B. Tech.(Mechanical Engineering)

UNDER THE GUIDANCE OF

Prof. Prof. L. R. Patil Mr. Dhiraj Patil

Assistant Professor Assistant Manager (Engineering)
R.I.T.Rajaramnagar Elcom International Pvt. Ltd.

1. Title
“Value Stream mapping for wiring harnesses”

2. Relevance:

Now-a-days, success of manufacturing industry is largely determined by its ability to rapidly

respond to market changes and to immediately adjust to customer needs. This has resulted in an
increasing demand for development of systems that can cope with agility and efficiency to these
demands. The goal of every industry throughout the world is of increasing production and
reducing waste in production. However, production and waste management and control is the
biggest challenge in achieving cleaner production. Organizations need to be globally competitive
by producing quality product with cost efficiently and providing the goods to the customer
timeously.

The production processes should be such that they eliminate non-value adding processes or
activities within the production system and any processes which generate excess waste. Waste
takes many forms and can be found at any place any time. It may be found in procedures,
processes and product design and operations. Waste consumes resources but does not add any
value to the product. Waste is anything other than the minimum amount of equipment, efforts,
materials, parts, space and time that are essential to add value to the product.

Lean Manufacturing methods are being increasingly implemented around the world, with aims to
eliminate waste and inefficiency from the manufacturing process, leading to lower costs and
greater competitiveness for manufacturers. Lean means manufacturing without waste.

Value stream mapping, thus involves all steps, both value added and non-added, required to
complete a product or service from beginning to end, making process more visual in order to
identify hidden wastes by showing bottlenecks, rework or waiting that affect the flow of product
or service. Value stream mapping is an enterprise improvement tool to assist in visualizing the
entire production process, representing both material and information flow.

3. Present Theories and Practices

1. Z standardization is implemented to analyze various production processes.

2. 5S principle is implemented at production line.
3. Kaizen charts are used for continuous improvement.
4. 3M principle is implemented for waste control.
 5. Most of activities of production planning and control are done by engineering
department.

4. Problem Statement

Over last 5 years wiring harness department of Elcom Internationals Pvt. Ltd. has experienced
speedy expansion and high demand levels; however their current processes and planning is not
much effective in storing, production and warehousing, etc to meet customer demands at
appropriate time, as their processes are over constrained and insufficient with the increase in
customer demand due to improper production planning and control. They are experiencing
following problems in the organization: increased inventory levels (in ware house and
production), poor care and control of materials, poor material flow patterns, poor productivity
and efficiency, unstable production lines, production time held due to raw material shortage, loss
of time due to poor material placement and visibility, decreased efficiency, improper planning,
etc.

5. Objective of the Work

1. Perform time study for various processes used for manufacturing the harness.
2. Create current state map for current production line.
3. Analyze the current state map to identify the wastes and bottlenecks that occur in
production processes.
4. Propose future state value stream mapping for continuous improvement by applying
various principles of lean manufacturing.
5. To design and develop proper production planning and control.

6. Proposed Work

I] Literature Survey

Mastan Singh, Er. Gurjinder Singh, Er. Jonny Garg, drawn a current state map for Fastener
Industry focusing on cycle time, lead time, inventory operators and distance. Analyzing the same
a future state map was proposed, which resulted in % reduction of every above parameter and
hence concluded that whenever there is product from customer, there is value stream mapping.
Value stream mapping is powerful tool not only to highlight process inefficiencies, transactional
and communicational mismatches, but also guide about improvement areas.
K. Eswaramuthi, P.V.Mohanram, presented the application of lean concept in terms of value
added activities and non-value added activities. Analysis of same is done for inspection process
of manufacturing industry, giving % of value added activities and non-value added activities.
Analysis concluded that some supporting activities like preparing equipment, part, report,
cleaning and system updation, etc are essential non-value added activities. But most non-value
added activities like unnecessary transportation, motion, over processing, etc are waste causing
increase in cycle time.

Soniya Parihar, Sanjay Jain, Dr. Lokesh Bajpai, drawn and analyzed current state and future state
maps for assembly processes of tractor parts. This study resulted in reduction of processes lead
time to 3.50 days and product cycle efficiency was increased to 0.476%. This study also states
importance of value stream mapping as an essential tool for realizing lean manufacturing in
actual production settings.

Wolfgang Apel, Jia Yong Li, Vanessa Walton, drawn a current state and future state maps for
Central Industrial Supply stating that biggest part of current lead time is inventory time, more is
work in progress (WIP), longer is lead time. Value stream mapping has proven to be an effective
way to analyze a company’s current production state and also helps in pointing out problematic
areas.

Rahani A.R., Muhammad Al-Ashraf, drafted current state map and future state map front disc
D45T and concluded that value stream mapping reveals obvious and hidden wastes that affected
productivity. Value stream mapping is applied to assess the expected impact of change in
production process resulted in saving i.e. lowering rejection rates.

Maxwell Dzanya, Caroline Mukada, identified specific actions required to eliminate non-value
added activities in Glide Industry by drafting present state and future state value stream maps.
This study stated that value stream mapping have been proven to be greatly useful tool to
eliminate some wastes in cycle and also finds that there are various wastes to be eliminated
during which lean becomes habit or culture. After value stream mapping study lead time was
reduced to 60.88%, processing time was reduced by 4%, and reduction in manpower was 25%.

II] Work Plan:

Value stream
Scope
 Determine value stream to be improved

Draw the current state map taking every single

Current state map factor into consideration

Analysis of current Study the current state map to find the

state map improvement points according to lean principles

Considering the above improvements, draft the

Draft future state map
future state map

Implementation plan Develop a plan of implementation to realize

improvements (what, who, when)

Implementation of The goal of determined value stream mapping

improvement plan

7. Plan of Proposed Work:

Sr.No Activity /Month Jan Feb Mar Ap May

r

       
Induction of all departments and brief study
1 of all processes carried out in wiring
harness department
2 Finding out problem in current processes          
and finalization of project. Determining
scope of value stream

3 Drafting current state value stream map          

4 Analyzing current state map and drafting          

future state value stream map according to
lean principles
 5 Implementation of improvement plan,          
finding results for same and concluding.

8.Facilities

1. Certified advanced engineering lab

2. Z standardization data form previous years
3. Upcrest – Enterprise resource planning software
4. AutoCAD (2007) software
5. Central library

9. Project Duration :January 2019 to May 2019.

References

[1] Mastan Singh, Er. Gurjinder Singh, Er. Jonny Garg, “Value Stream Mapping: A Case
Study of Fastener Industry”, IOSR Journal of Mechanical and Civil Engineering, Volume
12, Issue 5 Ver. III, 07-10, Sept-Oct 2015.
[2] K. Eswaramurthi, P.V. Mohanram, “Value and Non-Value Added (VA/NVA) Activities
Analysis Of An Inspection Process- A Case Study”, IJERT, Vol 2, Issue 2, Feb 2013.
[3] Ohno, Taiichi, “Toyota Production System: Beyond Large-Scale Production, Productivity
Press” (1988) ISBN 0-915299-14-3.
[4] Rhonda R. Lummus, Robert J. Vokurka & Brad Rodeghiero, “Improving Quality through
Value Stream Mapping: A Case Study of a Physician‟s Clinic” Journal of Total Quality
Management, October 2006, Vol. 17, No. 8, 1063–1075.
[5] Maxwell Dzanya, Caroline Mukada, “Value stream mapping in glide manufacturing: A
case study of Insti-Tools in Zimbabwe”, International Journal of Science, Technology
and Society, Vol. 3, No. 2-2, 2015, pp. 6-10.
[6] Soniya Parihar, Sanjay Jain, Dr. Lokesh Bajpai, “Value Stream Mapping: A Case study
of Assembly Process”, IJERT, Vol. 1 Issue 8, October - 2012

Date: 23/03/2019
Place: R.I.T. Rajaramnagar.
Ms. Karpe Vijaya Sudhir Prof. L.R. Patil Mr. Dhiraj Patil
Student College Mentor, Industry Mentor
B.Tech-Mechanical Engg. Dept. R.I.T. Rajaramnagar (Elcom International Pvt. Ltd.)
Roll No: 1656009

Prof. R.A. Patil Prof. G.L. Suryawanshi Dr. S.K. Patil,

TPC-Mechanical Engg. Dept. Four Track Coordinator, Head-Mechanical Engg. Dept.
RIT, Rajaramnagar. Mechanical Engg. Dept. RIT, Rajaramnagar.
RIT, Rajaramnagar.