International Journal of Mechanical Engineering and Technology (IJMET)

Volume 7, Issue 6, November–December 2016, pp.443–448, Article ID: IJMET_07_06_043

Available online at
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ISSN Print: 0976-6340 and ISSN Online: 0976-6359
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APPLICATION OF VALUE STREAM MAPPING IN

BHUJIA MANUFACTURING
Deepak Sharma
Department of Mechanical Engineering, ECB Polytechnic College, Bikaner, Rajasthan, India

Alok Khatri
Department of Mechanical Engineering, Govt. Engineering College, Ajmer, Rajasthan, India

Dr. Y B Mathur
Department of Mechanical Engineering, Govt. Polytechnic College, Bikaner, Rajasthan, India

ABSTRACT
Value stream mapping is an enterprise improvement tool to help in visualizing the entire
production process, representing both material and information flow. A value stream is all the
actions (both value added and non-value added) required to bring a product through the main
flows essential to every product for the production flow from raw material into the arms of the
customer. Value stream mapping (VSM) is a tool of lean manufacturing. The ultimate goal of Value
stream mapping is to identify all types of waste in the value stream and to take steps to try and
eliminate these.
In the present research paper, a food industry (Bhujia manufacturing industry) have been
considered with current state maps and future state maps after following the different steps starting
from the detailed time study for mapping the processes from raw materials to final product. Value
stream mapping captures the information at individual’s stations about cycle time, set up time, WIP
(Work in Process) inventory, manpower requirement and the information flow from raw materials
to final product. The overall non value added time is reduced during Bhujia manufacturing
process.
Key words: Value stream mapping, Lean manufacturing, Non value added time
Cite this Article: Deepak Sharma, Alok Khatri and Dr. Y B Mathur, Application of Value Stream
Mapping in Bhujia Manufacturing. International Journal of Mechanical Engineering and
Technology, 7(6), 2016, pp. 443–448.
http://www.iaeme.com/ijmet/issues.asp?JType=IJMET&VType=7&IType=6

1. INTRODUCTION
Value stream mapping is visualization and streamlines work processes using the tools and techniques of
Lean Manufacturing. VSM help to identify demonstrate and decrease waste in the processes. Waste is any
activity that does not add value to the final Product. [1]

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 Deepak Sharma, Alok Khatri and Dr. Y B Mathur

Various terminologies used in VSM are discussed as below:

• TAKT Time - The rate which a company must produce a product to satisfy its customer demand. [2] It is
calculated by dividing available working time per day (in minutes or seconds) to customer demand per day
(in relevant units).
• Production Lead Time - It is the total time a component takes in its ways through the shop floor, beginning
with arrival of raw material to shipment of finished goods to customer.
• Value Adding Time - It is the time which is utilized in adding actual value to the product.
• Current State Map - It describes the existing position of shop floor of any manufacturing facility.
• Future State Map - It describes the future position of shop floor of any manufacturing facility in order to
bring some improvement.
• Kanban - It is a signal in Japanese word that means card and which is used to reduce inventory.
• Pull Production - Producing exactly according to the pace of customer requirement.
Duranik Tomas, Markus stopper and Juraj Ruzbarsky (2011) described the application of value stream
mapping to identify hidden reserves and avoid bottlenecks. The aim behind the application of VSM was to
identify any type of waste and develop a current state map. Then they described an ideal state showing
only zero waste processes and finally a future state that could give answers on how to improve the
production flow and efficiency, to reduce production costs and to increase flexibility. [3]
According to Rahul R Joshi, G.R.Naik (2012), Value stream Mapping is used to identify the current
process of small scale industry. The current state map is used to identify the wastes. A future state map is
created with the waste activities eliminated and improve process cycle time and reduce work in process
inventory. [4]
Dinesh and A. Prabhukarthi (2013) explain value stream mapping in pump manufacturing industry.
They draw current and future state map were developed with the objective if improving productivity
according to customer requirements. [5]
Priyank Srivastava, Dinesh Khanduja and V.P. Agarwal (2014) proposed a study with purpose of
developing a plan for reducing lead time and increasing throughput in a product manufacturing plant by
using value stream mapping. The plant produces rubber screening media and wear products used in mining
and aggregating industry. The rubber manufacturer was inefficient due to poor product flow. [6].
Dighe and Kakirde (2014) defined value stream mapping as a lean manufacturing tool for
implementing lean initiatives in production process through systematic data capture and analysis. This tool
has been used to document current lead time inventory levels and cycle time to determine the ratio of value
added to total lead time of the product line being analyzed. A case study of pump manufacturing company
has been carried out and it was observed from current state map that the total lead time for the product was
54 days, inventory was 33 days and value added time was 0.55 hrs. [7].
Paranitharan (2015) carried out a case study based of VSM in Brass Lamp Manufacturing. A seven
step methodology was used to eliminate non value adding activity for productivity improvement and to
study the impact of VSM on industry. [8].

2. VSM METHODOLOGY
VSM has four major steps as given by Rother and Shook. [9].
• Select a product family.
• Draw current state map.
• Draw future state map.
• Develop work plan for implementation future state.
Value stream Map uses special symbols to represent where there is waste in manufacturing process and
to find ways to eliminate that waste. VSM symbols are shown as below

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 Application of Value Stream Mapping in Bhujia Manufacturing

Figure 1 VSM Symbols

3. CASE STUDY
A case study was conducted at Bhujia Industry and some of the observations were taken in implementing
VSM.

3.1. Selection of Product Family

The first step is the selection of the product family from the product mix for study. This critical product
family should be chosen after studying the product mix thoroughly. This product family will be ground for
further study.

3.2. Current State Map

The Figure 2 shows the current state value stream mapping of Bhujia manufacturing. All the data for
current state map were collected with the consultation of workers, supervisors, engineers and managers.
During the manufacturing process of Bhujia, various processes are identified i.e. mixing, moulding, frying,
draining and packaging process. In the current state mapping of Bhujia manufacturing, cycle time is the
value added time. The waiting time and set up time are non value added time. In the current state value
stream mapping "Takt Time" is calculated. It is calculated by dividing the total available time per day by
the daily customer demand. As per requirement of 15000 Kg. in 8 hr. shift, Takt time is calculated as:

Available working time 8 x 60 x 60

Takt Time = = = 1.92 Sec./Kg.
Customer demand 15000

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 Deepak Sharma, Alok Khatri and Dr. Y B Mathur

To complete the value stream map, a timeline is added at the bottom of the map recording the value
added time and non value added time. Finally, it is found that about 40 min. were value added activities,
compared to 14.70 min. of non value added activities.

3.3. Future State Map

Thee Figure 3 shows the future state value stream mapping of Bhujia manufacturing. A future map
identified improvement to be made to the value stream that will eliminate the waste. During the
manufacturing process of Bhujia, in the moulding process, weighted mixed floor is pressed into the mould
cavity. In the moulding process, set up time consumed is 1.83 min., which will be reduced. In the
packaging process, waiting time consumed is 2 min., which will be reduced. In the future state value
stream mapping of Bhujia
hujia manufacturing, set up time is reduced by redesigning the jigs and fixtures during
moulding process, which reduces the manual operation. Hence set up time is reduced from 1.83 min. to
0.61 min. The waiting time is reduced in packaging process by reducing
reducing gap between draining process and
packaging process. Hence waiting time is reduced from 2 min. to 1.33 min. Thus overall non value added
time can be reduced from 14.70 min. to 12.84 min. during Bhujia manufacturing process.

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 Application of Value Stream Mapping in Bhujia Manufacturing

4. RESULTS AND DISCUSSIONS

DISCUSSI
Table 1 shows the reduction of set up time and waiting time of Bhujia Manufacturing.

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 Deepak Sharma, Alok Khatri and Dr. Y B Mathur

Table 1 Reduction of setup time and waiting time of Bhujia manufacturing

Time taken
Time taken in
in future
current state
S. Time state value Technique applied to reduce Reduction
value stream
No. (Activity) stream time of time
mapping
mapping
(min.)
(min.)
Redesigning the jigs and
1. Setup time 1.83 0.61 fixtures during moulding 66 %
process in fryer machine.
Reducing the gap between
2. Waiting time 2 1.33 draining and packaging 33 %
process.

5. CONCLUSION
VSM is a powerful tool for lean manufacturing and it is a very effective technique for identification and
reduction of various types of wastes. It links people, tools, processes and even reporting requirements to
achieve lean goals. It provides clear and concise communication between management and shop floor
teams about lean expectations, along with actual material and information flow. The result of the case
study shows that the waiting time can be reduced from 2 min. to 1.33 min. Thus overall non value added
time may be reduced from 14.70 min. to 12.84 min. during Bhujia manufacturing process.

REFERENCE
[1] R.M. Belokar, Vikash Kumar, Sandeep Singh Kharb, An Application of Value Stream Mapping in
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