Lean implementation and its benefits to production industry

Purpose – The purpose of this paper is to discuss the lean implementation process and its quantified benefits for the production industry with the help of value stream mapping (VSM). Both current and future state maps of the organization's shop floor scenarios are discussed using VSM techniques in order to highlight improvement areas and to bridge the gap between the existing state and the proposed state of shop floor of the selected industry. Design/methodology/approach – VSM process symbols are used to discuss lean implementation process in the production industry. The existing status of the selected manufacturing industry is prepared with the help of VSM symbols and improvement areas are identified. Some modifications in current state map are suggested and with these modifications a future state map is prepared. Findings – After comparison of the current and future state of shop floor of the selected industry it is found that reduction in lead time was 83.14 percent, reduction in processing time was 12.62 percent, reduction in work‐in‐process inventory was 89.47 percent, and reduction in manpower requirement was 30 percent. The rise in productivity per operator was 42.86 percent. Research limitations/implications – The findings are limited due to the focused nature of the case study and further cost‐benefit analysis can be carried out. Practical implications – This paper will be very useful for the researchers and practitioners for understanding lean implementations and its derived benefits. Originality/value – The paper is a real case study showing lean implementation and its benefits for the production industry.