Application of value stream mapping as a method to reduce cycle time to support lean manufacturing system

In the manufacturing industry, lean manufacturing becomes popular as a beneficial way in the pursuit of better system efficiencies. The purposes of this study were to identify waste using lean manufacturing technique, determine causes to the waste through the value stream mapping method and to propose solution to improve workplace environment. Asian Composite Manufacturing Sdn. Bhd. (ACM) has been chosen as the company to conduct case study for this research. ACM is a joint venture company based in Bukit Kayu Hitam, Kedah, Malaysia owned equally by The Boeing Company and Hexcel Corporation. The business of the joint venture is the manufacturer of flat and contoured primary (Aileron skins, spoilers and spars) and secondary ( flat panels, leading edge, trailing edge and MISC component) structure composite bond assemblies and sub-assemblies for aerospace industries. There are some waste activities identified during observation including unnecessary transportation, excessive motions, inventories and waiting. In order to reduce this waste, some of lean manufacturing tools are used. Examples are Just-in-Time manufacturing (kanban system, continuous flow and takt time production planning), 5S, kaizen improvement, value stream mapping and production preparation process (3P). As a result of the use of these tools reduces lead time, increase efficiency of value added activities and eliminates some non value added activities. The tools suggested to be use in this study are pull system, takt time planning, visual control, kaizen, 5s and continuous flow. The results of this study indicated that implementing lean manufacturing system can improve the process performance by eliminating 7 types of waste. The main tool to be used in this study is Value Stream Mapping (VSM).