Value Stream Mapping (VSM) is an important tool for implementing lean philosophy. The concept of Lean is a systematical approach to identify and eliminate waste through continuous improvement. The value stream initiates at the concept and ends when delivered to customer. In this case study a current state map is prepared and analyzed and suggested to improve the process. A case study is carried out at Lear Corporation Halol.
Keywords –Value Stream Mapping, Lean, Current State Map
Companies are continually striving to increase productivity and output of their operations. Their goal is to satisfy the customer with the exact product, quality, quantity, and price in the shortest amount of time. Lean has been originally created and defined as the process of eliminating waste.  Toyota along with the support a system to reduce or eliminate waste and non-value added activities from the various processes.  A value stream is the set of processes required to transform raw materials into finished goods that customer’s value. Mapping of the value stream aids the identification of value adding and non-value adding activities.  Some examples are listed below:
Cutting, Painting, Assembling etc.
Non-value added activities
Inspection, Sorting, Moving etc.
A value stream map is an end-to-end collection of processes that creates value for the customer.
Basically VSM has three types
1. Process VSM – In process VSM, material and information flow with in a particular cell or production line.
2. Factory level or door to door VSM –In factory level VSM, material and information flow within a four walls of a factory
3. Extended level VSM – Focusing material and informational flow of several companies.
In this paper work carried in a factory so choose a factory level VSM
2. Literature review
R.M.Belokar, Sandeep Singh Kharb, Vikas (2012) Kumar drawn current state map for automobile industry. The tunnel floor is taken for the case study. The cycle time of the welding process exceeds the takt time of the current state. By modifying the layout and welding operation the improvement has been made.
Value Stream Mapping is used to identify the current process of small scale industry. The current state map is used to identify the wastes and non-value added activities in the production process. A future state mp is created with the waste activity eliminated and improve process cycle time and reduce work in process inventory. (Rahul R Joshi, G.R.Naik (2012)).
Dinesh and A.Prabhukarthi (2013) explain value stream mapping in pump manufacturing industry. They draw current and future state maps were developed with the objective if improving productivity according to customer requirements. Rother and Shook (1999) have discussed that Value Stream Mapping is used to define and analyze the current state for a product value stream and design a future state focused on reducing waste, improving lead time and improving work flow. One of the...