Abstract—Toyota production system introduces the value stream mapping which is a method to evaluate and improve business functions. A value stream includes all elements both value added and non-value added which occur to a given product from its inception through delivery to the customer. Value Stream Mapping (VSM) mainly deals with three steps: current state map, future state map and action plan. Main steps to achieve a optimized value stream consists of selection of product family of high demand and low variety, forming a multidisciplinary team, understanding the customer demand, mapping the process, material and information flow, calculating the Takt time, lead time and change over time. Understanding and application of mapping symbols in designing material, process and information flow and data collection are vital parameter for the success of mapping. Work presented here is aimed at applying the VSM technique for leading seat manufacturing company. It uses foam (chemicals), frame (metal), trim (fabric or leather) and plastic parts as a raw material. There is a wide scope for process improvements through enhancing the supply chain from supplier end to the customer end which will results in tangible and intangible benefits such as time, cost and fatigue. Implementation of VSM tools has resulted in self examination of the present process performance against the customer demand. It also guides to the future state via scientific techniques like time and motion study, NVA reduction, Kaizen, 5S and focuses on root cause of the problem.

Index Terms—Information flow, Inventory management, Pacemaker process, Value stream mapping

Cite: Manoj Bhalwankar and Sachin Mastud, "Applying Value Stream Mapping for Improvements in Automotive Seat Manufacturing Processes," International Journal of Mechanical Engineering and Robotics Research, Vol.3, No.4, pp. 164-177, October 2014.