Mapping the path to efficiency: harnessing value stream mapping (VSM) and lean tools for streamlined electronic device manufacturing

Abstract

Purpose Optimizing manufacturing processes addresses operational challenges and yields significant benefits across the business spectrum. This study aims to comprehensively analyze a manufacturing process through value stream mapping (VSM), aiming to streamline operations, reduce production lead times and minimize work-in-process (WIP) inventory levels. These improvements directly enhance competitiveness, customer satisfaction and overall business success, enabling a swift response to market demands, timely delivery of high-quality products and cost-effectiveness. Design/methodology/approach The approach integrates current and future-state VSM concepts with Lean tools across four stages: problem definition, current-state VSM analysis, future-state VSM design and improvement implementation. A team assembled to improve the manufacturing process for electronic devices has successfully implemented this approach. Findings Implemented improvements significantly reduced WIP inventory (88.8% equivalent to $572,171 annually) and production lead time (from 28.26 to 3.21 days), enhancing operational flexibility and competitiveness. Streamlined processes led to a 13% decrease in cycle time and a notable reduction in daily rework (63.6%), amounting to $118,127 annually. Labor reduction (45.5%) yielded annual savings of approximately $594,000, with affected individuals successfully transitioning to other roles, highlighting the effectiveness of lean methodologies without job cuts. Originality/value This initiative exemplifies the effective use of VSM and Lean tools in optimizing an electronic device manufacturing operation that produces 43 products across various processes. By leveraging these methodologies, this research offers valuable insights into enhancing production efficiency, resulting in shorter production lead times, reduced cycle times and significant decreases in WIP inventory and rework.