A lean manufacturing approach to waste minimization: a case of industrial rack plant

The concept of Lean Manufacturing is a methodology focused on eliminating waste in various activities through the application of five key principles: defining value, mapping the value stream, ensuring flow, establishing pull, and pursuing perfection. Starting with the identification of value based on product sales, it was determined that industrial rack product is the top-selling product. A Current Value Stream Map (Current VSM) was created to illustrate value-adding activities within the production process and highlight sources of waste. The analysis identified inefficiencies in the production processes of side frames, beams, and packaging, which hindered the ability to meet the target takt time of 60 seconds per unit. Once the processes requiring improvement were identified, strategies for optimization were developed, leading to the creation of an Improved Value Stream Map (Improve VSM). The implementation of waste reduction measures resulted in a significant decrease in production cycle time, from 104 seconds per unit to 60 seconds per unit—a reduction of 42.31%, enabling compliance with the target takt time. Ultimately, the complete elimination of waste led to the creation of an Ideal Value Stream Map (Ideal VSM). This was achieved by incorporating pull system and continuous u-shaped line principles and consolidating workstations to minimize non-value-adding activities. These improvements not only enhanced production efficiency but also maximized the ability to meet customer demands and contributed to building a competitive advantage.