Value stream mapping as a versatile tool for lean implementation: an Indian case study of a manufacturing firm

Purpose – The purpose of this paper is to explain how value stream mapping (VSM) is helpful in lean implementation and to develop the road map to tackle improvement areas to bridge the gap between the existing state and the proposed state of a manufacturing firm. Design/methodology/approach – Through this case study, the existing stage of manufacturing is mapped with the help of VSM process symbols and the biggest improvement areas like excessive WIP, lead time, cycle time, are identified. Some modifications in current state map are suggested and with these modifications future state map is prepared. Further TAKT time is calculated to set the pace of production processes. Findings – Current state and future state of manufacturing of a firm are compared and witnessed: 92.58 percent reduction in lead time, 2.17 percent reduction in processing time, 97.1 percent reduction in WIP and 26.08 percent reduction in manpower requirement. Research limitations/implications – The findings are limited due to the focused nature of the case study. VSM can also be applied to the process industry as well as to the service sector. Practical implications – This case study shows that VSM is a powerful tool for lean implementation and allows every industry to understand and continuously improve its understanding towards lean manufacturing. Originality/value – This paper is a real case study showing VSM applications for lean implementation.