In a competitive world, companies face efficiency requirements in their operations and are forced to cost reduction. Customers require improvement in production lead times, costs, and service levels and companies need to meet customer requirements to survive.
Nowadays, organizations can maintain their competitive approach with the evolution from a product-oriented vision to a customer-oriented vision. Lean manufacturing, which has become the main approach in organizations, is also one of the key tools of the automotive industry. As a result, companies began making a tremendous effort to increase their efficiency. Though, lean manufacturing principles have been conducted in order to reduce the production lead times, costs and to improve service levels. There are several lean techniques, which allow lean production and eliminate waste to meet customer needs as and when requested. One of the most useful and visual techniques is the value stream mapping (VSM), which defines all value-added and non-value-added process activities in the system in terms of time, cost, and labor.
In this study, the VSM technique is used in a company that is a supplier of original equipment manufacturer in the automotive sector, together with many lean manufacturing philosophy methods to create an efficient production system. The aim of this study is cycle time reduction, inventory reduction, and internal logistics time reduction, as well as eliminating mixes of similar materials and most importantly reducing scrap cost by analyzing nonconforming material flow. The current state value stream map of an automotive oil pump company is drawn and the improvement actions are discussed with the management team. Technique for Order Preference by Similarity to Ideal Solution (TOPSIS) approach is suggested and the proposed approach is performed to decide the order of corrective actions. The corrective actions are performed using lean manufacturing system techniques such as kaizen, 5S. Consequently, the future state value stream map was revealed.
Anahtar Kelimeler: Value stream mapping, lean manufacturing, kaizen, automotive, TOPSIS.