Application of lean production with value stream mapping to the blasting and coating industry

Abstract

Lean production involves a variety of principles and techniques, all of which aim to eliminate waste and non-value-added activities at every production or service process. To stay competitive, many Australian owners in the blasting and coating industry have sought to improve their production process productivity and human performance. The purpose of this study is to evaluate the feasibility of existing lean principles by using Value Stream Mapping (VSM) in the blasting and coating industry. A real case is selected as a model, both current and future states of shop-floor production scenarios are discussed using value stream concepts. This is analysed along with calculations of cycle time, work-in-process inventory, and waiting time. A framework of lean improvement is proposed which includes: (1) waste elimination by using techniques of standardisation, supermarket, and pull scheduling system; (2) workforce involvement; and (3) client integration. The results showed that the product delivery rates could be significantly increased through lean implementation.