Abstract:
Improvement of product flow by means of applying lean principles, including value stream
mapping tool has become an important component in an attempt of many companies worldwide
to make transition from traditional production to the lean manufacturing system. The topic of this
master thesis takes Pakistan Springs Private Limited as a case that produces different high
quality components of auto parts market. This report is an attempt to understand and analyze the
problems in the product flow using the example of Pipe Fork family of products used in
manufacture of front shock absorber of Atlas Honda motorbike.
The purpose of this case study has been to identify, analyze and propose solutions for wasterelated problems in the Pipe Fork product flow within the facility, by applying the lean thinking
principles and the data collection methods.
The proposed case study methodology combines both theoretical and empirical approach. Data
collected in interviews with the management and workers, and observations on the workshop
floor have constituted the input for the value stream mapping and process activity mapping
methods. The value stream mapping method has been applied to construct the current state map
of the Pipe Fork value stream and identify the wastes. As a result future state value stream map
has been developed alongwith implementation framework for transition to lean manufacturing.
It has been concluded from the constructed current state map of Pipe Fork value stream that the
most critical wastes are waiting, transportation, unnecessary inventory, unnecessary motion and
defects. Furthermore, the improper workshop layout has been recognized as the main reasons for
the wastes. The measures to reduce the identified wastes have been pointed out. It has been
proposed that by reducing variations in the production processes i.e. unplanned machine
downtime, skill of workers, quality of machine parts, power breakdowns and unwarranted
fluctuation in customer demand schedule not only can reduce product lead time and cost but also
improve over equipment effectiveness. Application of pull production techniques, slight
improvement in machine layout and forming machine cells can improve flow of pipe fork
product family within the facility.
