Implementation of Lean Concepts Using Value Stream Mapping in Automotive Firm

  • Abhishek Deokar
  • S. Aravind RajEmail author
  • K. Jayakrishna
  • H. Abdul Zubar
Conference paper
Part of the Lecture Notes in Mechanical Engineering book series (LNME)


Lean manufacturing is the concept used to identify potential waste in industries to survive in competitive market. Lean concept was introduced by automotive firm known as Toyota Production System (TPS). The need of lean facilitates increase in productivity. Value stream mapping (VSM) is a lean tool to identify value-added and non-value-added activities in production line. This chapter focuses on studying the current state map of an automotive firm and to implement value stream mapping (VSM) to design future state map using appropriate lean tools to increase the productivity and eliminate non-value-added activities. The study was conducted on crankshaft line of an engine shop in an automotive firm. After conducting study, successful implementation of the VSM tools resulted in the reduction of cycle time by 56, 227, and 155 s of oil-hole drilling, induction hardening, and grinding, respectively. The productivity was improved by 24 units on an average after complete implementation of future state VSM.


Lean manufacturing Value stream mapping (VSM) Lead time Quality improvement Kaizen 


  1. 1.
    Singh H, Singh A (2013) Application of lean manufacturing using value stream mapping in an auto-parts manufacturing unit. J Adv Manage Res 10(1):72–84. Scholar
  2. 2.
    Faulkner W, Badurdeen F (2014) Sustainable value stream mapping (Sus-VSM): methodology to visualize and assess manufacturing sustainability performance. J Clean Prod 85:8–18. Scholar
  3. 3.
    Vinodh S, Selvaraj T, Chintha SK, Vimal KEK (2015) Development of value stream map for an Indian automotive components manufacturing organization. J Eng Des Technol 13(3):380–399. Scholar
  4. 4.
    Belokar RM, Kumar V, Kharb SS (2012) An application of value stream mapping in automotive industry: a case study. Int J Innov Technol Explor Eng 1(2):152–157Google Scholar
  5. 5.
    Hines P, Rich N (1997) The seven value stream mapping tools. Int J Oper Prod Manage 17(1):46–64. Scholar
  6. 6.
    Haefner B, Kraemer A, Stauss T, Lanza G (2014) Quality value stream mapping. Procedia CIRP 17:254–259. Scholar
  7. 7.
    Lacerda AP, Xambre AR, Alvelos HM (2016) Applying value stream mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry. Int J Prod Res 54(6):1708–1720. Scholar
  8. 8.
    Azizi A, Manohanaran P (2015) Designing a future value stream mapping to reduce lead time using SMED-a case study. Procedia Manuf 2:153–158. Scholar
  9. 9.
    Tyagi S, Choudhary A, Cai X, Yang K (2015) Value stream mapping to reduce the lead-time of a product development process. Int J Prod Econ 160:202–212. Scholar
  10. 10.
    Rosa C, Silva FJG, Ferreira LP (2017) Improving the quality and productivity of steel wire-rope assembly lines for the automotive industry. Procedia Manuf 11:1035–1042. Scholar
  11. 11.
    Vamsi Krishna Jasti N, Sharma A (2014) Lean manufacturing implementation using value stream mapping as a tool: a case study from auto components industry. Int J Lean Six Sigma 5(1):89–116. Scholar
  12. 12.
    Venkataraman K, Ramnath BV, Kumar VM, Elanchezhian C (2014) Application of value stream mapping for reduction of cycle time in a machining process. Procedia Mater Sci 6:1187–1196. Scholar
  13. 13.
    Verma N, Sharma V (2016) Energy value stream mapping a tool to develop green manufacturing. Procedia Eng 149:526–534. Scholar

Copyright information

© Springer Nature Singapore Pte Ltd. 2019

Authors and Affiliations

  • Abhishek Deokar
    • 1
  • S. Aravind Raj
    • 1
    Email author
  • K. Jayakrishna
    • 1
  • H. Abdul Zubar
    • 2
  1. 1.Department of Manufacturing Engineering, School of Mechanical EngineeringVellore Institute of TechnologyVelloreIndia
  2. 2.Department of Industrial Engineering, Faculty of EngineeringKing Abdulaziz UniversityJeddhaKingdom of Saudi Arabia

Personalised recommendations