Background of the Study

Background of the study

Lean Manufacturing a cycling effort to reduce or eliminate waste or any activities that consume resources without adding values in design, distribution, manufacturing and customer service processes also known as the Lean production. Lean manufacturing as compared to the mass product uses very less resources, human effort in the industry, and investment in tools, reduces engineering hours and develops new products in half the time allotted. In early 1900’s Henry Ford created flow product, soon after Toyota Production System (TPS) developed and introduced the concept of lean manufacturing in the manufacturing industry. Value stream mapping is a kind of lean manufacturing tool, originated from the Toyota Production System (TPS) is generally known to be the “material and information flow mapping” (Andrade, Pereira & Del Conte, 2015). This tool of mapping is used initially for identifying, demonstrating and decreasing waste. It also creates a flow in the process of manufacturing. Value stream mapping is created merely by pencil and paper. But now a day advanced mapping can be done by Microsoft excel or Microsoft Visio. According to TPS, they call ‘muda’ to the seven original wastes (Andrade, Pereira & Del Conte, 2015). With respect to make the environment workable from lean manufacturers the seven wastes should be identified and depleted. VMS has proved its effectiveness on identifying and eliminate waste in an organization with identical product routings like assembly facilities.

Research Aim and Objective

Analyzing the cultural and technological challenges related to lean manufacturing. There are several ways to analyze and identify the challenges regarding lean manufacturing implementation (Andrés-López, González-Requena & Sanz-Lobera, 2015). On the basis of expert opinions, nominal techniques, literature reviews and brainstorming the key challenges has been found (Ar & Al-Ashraf, 2012). The major challenges which are highlighted are in Table 1.

Serial No. Save Time On Research and Writing Hire a Pro to Write You a 100% Plagiarism-Free Paper. Get My Paper	Cultural and technological challenges in Lean Manufacturing
1. 2. 3. 4. 5. 6. 7. 8.	Unrealistic Demand from customers Expectations of customers Expectation of top-management Inventory Management methods Project implementation Effective knowledge communication and information transfer Lack of common vision and training Non-lean behavior (Belekoukias, Garza-Reyes & Kumar, 2014)

Table1: Challenges in Lean Manufacturing

Aims of the study

To identifying the Value Stream Mapping process application in Lean Manufacturing. The technique of mapping the materials and information flow of all components and the relatable flow of all the components and the sub-assemblies in a value-stream that generally includes the suppliers, manufacturing and distribution to customers is defined as the Value Stream Mapping (VSM) (Ar& Al-Ashraf, 2012). The main motive of this case study is to identify the way of reducing the ‘muda’ from the environment by value stream manufacturing, how these technology are implemented, its effectiveness in daily life of the customers and the challenges regarding the cultural and technological aspect of lean manufacturing (Belekoukias, Garza-Reyes & Kumar, 2014).

Objectives of the study

The main objective of the VSM study:

• To analyze the significance of the Value Stream Mapping process
• To critically analyze the applications of the Value Stream Mapping process
• To critically evaluate the concept of the Lean Manufacturing
• To critically analyze the application of Value Stream Mapping process in Lean Manufacturing

Research Question

1. How the Value Stream Mapping process can be effectively used in the Lean Manufacturing in different industries?
2. How are these technology implanted in the manufacturing industry?
3. How does Value Stream Mapping affect the common people’s daily life?

Problem Statement

The case study investigates the change in manufacturing industry, affecting the daily life of customers. Since, this study is focused on the Value Stream Mapping in Lean Manufacturing therefore the data collected from the case study is based on the effectiveness of  value mapping in lean manufacturing in any manufacturing industry (Brown, Amundson&Badurdeen, 2014). The perspective of the manufacturing industries are not been taken broadly in this case study instead how these technology can be implemented has been discussed (Andrés-López, González-Requena&Sanz-Lobera, 2015). The problem is that there are still problems regarding the implementation of the projects. There are many expectations of higher authorities and customers on lean manufacturing but there is a lack in common vision of measurement tools for assessing any change towards lean implementation (Chen & Cox, 2012)

Research Aim and Objective

Rationale of the study

The case study on ‘Value Stream Mapping in Lean Manufacturing’ is selected to analyze the Value Stream mapping working as a power tool in lean manufacturing and to analyze the improvement areas for the current manufacturing industry determine the drawbacks of the technological approach. VSM helps firms to understand and improve the work towards becoming a lean enterprise and hence how the mapping can be implemented in various aspect of the industry such that it increases productivity, minimize the human effort, detonate the waste, manages the time and gives maximum privilege to the manufacturing industry.   

Research Methodology

Secondary data will be collected from the different types of previous research papers or journal articles written in the field of the research study. The websites and the annual reports of the different types of manufacturing organizations will be used for conducting the research study. Only qualitative secondary data would be gathered from the research study. This particular chapter discusses about the qualitative and quantitative approach toward the betterment of the manufacturing industry hence deals with the concern of waste depleted in all aspects of life (Brown, Amundson&Badurdeen, 2014). The lean manufacturing is the process regarding the elimination and reduction of wastes by using Value Stream mapping as a tool for analyzing and improving the flow of information and material requirement for the service to the customers.

Value Stream Mapping is a Lean Manufacturing that has been originated from the Toyota Production System (TPS). It was particularly used for the analysis of design flow of the material and information required to bring the product or service to the customer. This dissertation has two main objectives. The first literature review is an in-depth concept of value stream mapping, which focuses on value stream mapping tools. The application of value stream mapping in manufacturing industry. The literature review of value stream mapping provides an overview of this lean tool that offers a precise framework for the future study in the application of value stream mapping in the lean manufacturing industry. The second objective is to perform a case study on the selected topic and evaluating its outcomes and hence identify the drawbacks and how these could be overcome (De Steur et al., 2016). The value stream mapping helps in visualization of the work and targeted wastes, this enables the future improvement towards the betterment of states in manufacturing industry. Hence this section summarizes the literature review from several main aspects

The literature review is a vital part that sets the planning of the research. On the basis of the particular topic, by reviewing the literate of the research one can understand the concept and currently on some researches done on value stream mapping, various kinds of value stream mapping tools and the techniques to use the VSM for visualizing the project given in manufacturing industry and make the improvements respectively (Chowdary& George, 2012). In Lean Manufacturing, there is a lack in the consistent definition of lean amongst common people. The disagreement on the elements that comprises lean manufacturing and hence lack of the measurement tools makes it hard from manufacturing as well as service industry to change assessment towards lean manufacturing.

Aims of the Study

Concept of Value Stream Mapping

The term value stream was at first used in the book by Womack, Jones and Roos ‘The Machine that changed the world’ in 1990, and later discussed in Lean Thinking in 1996 by Womack and Jones. Later in another book written by Martin and Osterling the definition of Lean Manufacturing was described as “a value stream is the sequence of activities an organization undertakes to deliver on a customer request”. There are several types of value chain. The most important aspect is to deliver a good or service on request and which is eventually delivered to the end customer (De Steur et al., 2016). Value stream that supports the delivery of values are the one known as the value-enabler or support value stream.

The definition of Value explained as a capability provided to the customers in highest quality, at exact time and at an exclusively appropriate price of the product that a customer is buying. Value Stream Analysis is basically planning of the tools to optimize the results to eliminate wastes. Value Stream Mapping is basically the manufacturing environment that is described since the technique was used by the Toyota Motor Corporation which was called the “material and information flows”. The manufacturing industry focused on the understanding of the flow of material and information across the organization and how these could be used to improve the manufacturing industry any further (Faulkner &Badurdeen, 2014). Value Stream Mapping can provide an overview of the work that has been done through the entire system of the organization. The understanding of the different types of waste that may occur is important before knowing the tools provided in value stream mapping to eliminate these wastes. There are three types of operations; first one is Non-value adding, second is Necessary but non-value adding and third is the Value-adding. First one is ‘the pure waste with unnecessary actions’ that must be totally removed (Forno et al., 2014). The second involves the actions which are required but these could be wasteful. The process of conversion of raw materials in proper manufactured product with the help of Toyota production system according to Jones at 1995, these are waiting conveyance, excess stocking, faster-than-necessary pace, process of the manufacturing, unnecessary motions and correction of mistakes (Fullerton, Kennedy & Widener, 2013). The items that flow through value stream are: In manufacturing materials are considered as the items, in designing and development design planning are considered as the items, In services the external customers need are considered as the items and In admin the internal customers are considered as the items.

Concept of Lean Manufacturing

Lean is an idea toward manufacturing products that integrates collection of principles, techniques and tools in the process of business that optimizes productivity, assets, human resources and time, with the improvement of quality level of the manufacturing products and services to the customers.

 Lean Manufacturing is the concept of manufacturing mass products by use of less time, less effort, lesser space, improved quality and minimizing the defects (De Steur et al., 2016). There are some important objectives for the implementation of lean manufacturing like: Customers’ need at highest satisfaction, elimination of the total waste and utilization of effort at minimize rate.

Objectives of the Study

The essentials of lean manufacturing use some layouts for the process in which the manufacturing cells are arranged in parallel. There should be no storage material in every cell; instead there is a single piece of flow (Fullerton, Kennedy & Widener, 2013). Lean manufacturing basically aims on decreasing the waste. Types of wastes like: the efforts of transporting goods from one to another place sometimes get wasted, maintaining the balance of inventing excessive amount of raw materials and finished products, repairing damaged tools and correcting the malfunctions, maintain the over production etc. The roles of Lean manufacturing in an organization have techniques that are beneficial for increasing the profit and reduce the production costs (Gracanin, Buchmeister&Lalic, 2014). The main objective in any industry is to maximize the profit. So, it is requires studying and understanding the relation between profit, cost and sales in brief by the fallowing diagram:

 

Figure 2.1: Distribution of profit in Various Processes

(Source: Silva, 2012)

In Figure 1, the production cost and sales price along with the profit has been explained with respect to the lean manufacturing process and traditional process flow (Fullerton, Kennedy & Widener, 2013). Process 1 and Process 2 the technique oftraditional manufacturing and Process 3 the Lean manufacturing approach is used. The calculation related to the statistic:

Process 1

Profit = Sale Prize – Production Cost

Profit = 600 – 400 =  200

This satisfies the customer’s need but the organization will not be satisfied.

Process 2

Profit = Sale Prize – Production Cost

Profit = 700 – 400 =  300

The organization is satisfied but the customer does not.

Process 3

Profit = Sale Prize – Production Cost

Profit = 600 – 300 =  300

Both the organization and customer is satisfied.

Implementation and following of lean path leads to direct cost saving and helps in driving out the wastes (Fullerton, Kennedy & Widener, 2014). Lean manufacturing is very focused on customers and needs not very easily achieved. Hence, for improvement in organization from every aspect some techniques should be maintained within the parameters:

• Value Mapping
• Single Piece Flow
• Exchange of dies in single minute
• Inventory controls by card systems
• Concepts
• Maintenance of total productivity
• Visual management
• Optimization of line of production (Gracanin, Buchmeister&Lalic, 2014)

 

Figure 2.2: Lean Implementation Model

(Source: Rohana et al., 2013)

The lean implementation follows some specific path like the Customer’s satisfaction: This part deals with the exact requirement of the customers. The second part deals with the time management of the organization. The third part is the quality of service or product that has to be delivered (Haefner et al., 2014). The next intension of the company is always towards the improvement and development of the industry without implementation of any new ideas. The fifth part deals with the visual management of the product or service, this has to be attractive as well as the helpful to customers and the last part is the policy deployment of the lean manufacturing that concentrates on the ethical values and public issues of the waste depletion (Haefner et al., 2014).

The five main Lean Principles are associated with identification of the value, Value mapping, Create a flow of the manufacturing, Establishing pull and seek for perfection in the production (Henrique et al., 2015).

1. Identify Value: Specifying value accurately from the customer’s perspective, keeping knowledge of what kind of product and service, they want. Lean manufacturing defines the value of product merging with the customer’s view point as well.
2. Value stream Mapping: Specific activity identified by value stream,  that are converted to final product from raw materials and are required for the development of the services or the products eliminating non-value-adding wastes.
3.  Create flow: The flow from raw material to a complete product or service without any kind of interruption across the entire value stream.
4. Pull System: This concept is defining the production as authorized from a customer’s point of view.
5. Perfection: Identifying constantly and removing wastes along the value stream that would help in achieving perfection.

Research Question

Value stream mapping process has five major steps: The first one deals with the product that is either good or services have to be identifies and prepare a leadership accordingly. The second is foundation for the future state where accuracy should be maintained, third is the design future state that is creating a flow by eliminating waste, fourth is for creating the transformation plan of the product which includes accountability and timeframes for completing the process and lastly the implementation where the product is socialized and standardized (Herzog, & Tonchia, 2014).

The data collected here is in the graphical form, Time vs. Stakeholder value in innovation elements. From the graph it has been determined that the innovation elements like remanufacturing, redesigning, recovering, recycling, reuse and reduce the waste the main motive of the manufacturing industry. In sustainable manufacturing the graph goes higher since the innovative elements in economic development is depleted without the destruction of natural resources. The Green manufacturing in the environment is 3R based that is the graph goes partially diagonal, the green products are particularly renewed for renewable energy. The Lean manufacturing reduces the wastes by several ways like Value stream mapping refers to one of the process, this helps in reduction of wastes. The last is the traditional manufacturing which reduces wastes and renews them to the least but takes lesser time.  

The above sample of value stream mapping displays how customer value can be created in the various steps of manufacturing, production control and shipping process of the manufacturing. The lean manufacturing value stream mapping (VSM) are developed by several samples like: Production control, Value Stream Map, Quality Lean management, Quality lean manufacturing, and Quality value stream management. The above image is the production image in lean manufacturing.

The Analytical tools of lean management are: Value Stream Analysis and Mapping, Metrics-based process mapping and the Root cause analysis which includes- Five Why’s, Fishbone, Pareto, Problem tree and FMEA. Three kinds of research design are: Exploratory Research Design, Explanatory Research Design and Destructive Research Design. It is necessary to mention that Exploratory Research design is used while the issue related to the research is not properly explained (Novikov & Novikov, 2013). Exploratory Research Design is used for establishing the brief ideas along with the proved cause and effect of the research issue (Uprichard, 2013). However, Descriptive Research Design can briefly describe the relationship and the situation as well.

Benefits of Value Stream Mapping in Lean Manufacturing

Benefits of the value stream mapping are as follows:

1. Visualizing non-visible work like information exchanges can be done by using the visual unification tools. Visualizing non-visible work is the best way to understand the techniques of work done in industry.
2. Value stream map helps to create connections to customer that helps in focusing more on the customer’s perspective and hence delivers much more value to the organization (Herzog, & Tonchia, 2014).
3. Values stream mapping can merge disparate parts to a more collaborative organization by providing a more holistic system view for the customers.
4. At some macro level value stream mapping can simplify the work as well as the visualization of the work that helps in further strategic improvement in making the decision much better and faster.
5. Value Stream mapping helps in proper understanding to the concept for the new comers and clearing their place in the organization.

Hence, the Value Stream Mapping introduces the organization a full view to the work process starting from a customer’s request to the final fulfillment of the request. Mapping helps in understanding the deliverable of value to the customer and therefore highlights the work flow depending on the perspective of a customer. So as a result, the techniques of value stream mapping provide an effective way to develop strategic directions on better work designing and decision making. This helps in the growth of the country as well like Reduction the overhead costing for operations, saves a lot of space, controls the quality, sales are higher almost reaches double, saves production and service time which cuts up by 50% to 90%, processing queues cuts by 70% and continue the improvement of the industry.

Problem Statement

Challenges in Lean Manufacturing

The organization practicing lean manufacturing does not adequately absorb the advantages of the improvements. Organizations targets to market the benefits and then turn them to increase market share (Kasava et al., 2015). With the help of lean Manufacturing in this globalized age employees get an overview of the application of unseen dangers of rejection and tools present in the organization. Practicing Lean recompenses welfares but generates challenges as well like: Unrealistic Demand from customers, Expectations of customer, Expectation of top-management, Inventory Management methods, Project implementation, Effective knowledge communication and information transfer, Lack of common vision and training and Non-lean behavior (Kasava et al., 2015). Focusing on the tools not on the cultural change behavior is major issue challenging in the lean manufacturing since the cultural facts can lead to ethical dilemma of the company, Since the company’s first priority are the customers supporting them, hence to keep in mind the way and the products they want are the main and the major target of the industry (Lasa, Castro & Laburu, 2015). But also keeping in mind the value and material needed on the production, it should obviously not make the industry run in loss. The other challenge is to resist the change, change is inevitable and so does time. So creating a timeline within the change is quite a hard as well as essential task for any kind os manufacturing company. Lean project or effort is not aligned to the business case of nay industry. The higher management stays engaged and keep on challenging the employees for the improvement and development of value adding work and hence successes in implementation of lean in an organization (MohdYusof, Mat Saman & Kasava, 2013). Therefore, always a discipline is maintained in the organization, along with the continuous work done by the lean tools and exploring opportunities in large scale and ideas for improvement of the industry. It has been determined that unless and until the whole concept of lean manufacturing are implemented and embraced the industry cannot move any further towards improvement.

Conceptual Framework 

Figure 2.7: Conceptual Framework

(Source: Created by the author)

Research Methodologies give the largest aspect of research study that are even significant. This is because the research methodologies provide theoretical and systematic approach to reach the conclusion of the entire thesis. Research methodology comprises new and several important methods, techniques are also designed relating to the principles. This particular chapter focuses on the various aspects of Value Stream Mapping and Lean Manufacturing. Hence, relates to the procedures for selecting and implementing the designs in the industry. The discussion of theories of Veal (2006) on the research methodology helps in better understanding and analyzing the research topic. Application of the research methodology let people understand the adopted procedures for analyzing the research of the decision making and the role of branding with in the process. In 2005, Levine stated that the detailed process of the research methodologies can lead to some common errors which may create limits within the process of research. The lean manufacturing is the process regarding the elimination and reduction of wastes by using Value Stream mapping as a tool for analyzing and improving the flow of information and material requirement for the service to the customers. This research is done to understand the major aspects of value steam mapping in lean manufacturing.

Rationale of the Study

Method Outline

In this area of research study, as the research topic refers “Value Stream Mapping in Lean Manufacturing”, the research will follow the systematic approach toward the conclusion of the study (Ahram, 2011). Various highly significant approaches can be utilized to collect relevant data and information in this particular research study. In this research, Descriptive Research Design and Inductive Research Approach have been adopted for completion of this research study along with appropriate conclusion. Furthermore, this deductive approach may allow the researcher to conduct the research study based initially on secondary sources that helps in defining the value stream mapping and the influence of lean manufacturing in the industries (Alvesson & Sandberg, 2013).

 The development of Value Stream Mapping methodologies are based on application phases as identified by Rother and Shook. The initial phase of the methodology is to select product family. In this case study, the industry selected the manufacturer of Quantum 12 rope. It was selected because the process of production involved processes that are found in the rope manufacturing facility, while the other kinds of ropes were not involved in the processes (Alvesson & Sandberg, 2013). That means all the machines and the processes were present within the manufacturing facility and were used in the manufacturing of Quantum 12 rope. Quantum 12 is highly strengthen, light weighted, floating ropes that are preferred to grip on the capstan for its unique ability. Quantum 12 provides cut resistance and higher coefficient of friction which are equally high performable rope. Samthane coating that helps in excellent visibility and also includes abrasion resistance (Ahram, 2011). It includes applications like rig tow lines, offshore pick-up lines, winch lines and wire replacement.

• Current State Map

Information that is acquired for using each processes of rope manufacturing is how the current state map was created. This map includes, several steps in the stating of process from customer’s order receiving and delivering that order to the respective customer. The operation time of Data concerning, information flow, material flow and the inventory are recorded during the process. The current state map is divided into two major parts. First one is called the receiving order and the second is called the production processes.

 The Receiving Order: (1) Receiving customer order- the customer service, receives order from customer, checks and process the given order and send the information to the schedule of initial production. (2) Initial production schedule- This waits for several days to collect the orders received and make a list of the weekly production and hence purchase list. (3) Delivery of raw material- The time taken to purchase and deliver the raw material to the supplier. (4) Weekly production schedule- On arriving of the raw material takes few weeks to get proceed in to next level. (5) Shift scheduling- In this the rope supervisor assigns the schedule to the shifted supervisor. (6) Assigning process work- the shift supervisor assigns work to several other workers.

 

Table 2: Current state data for receiving order

The Production Process: (1) The twisting process set up- The warehouse materials (2) Twisting Process- (3) In stranding process the yarn packages must be used. (4) Braiding process- Strand is braided after the day it has been manufactured. (5) The packaging of the product takes place. (6) Shipping- The rope is places in the warehouse by the shipping department warehouse.

Research Methodology

 

Table 3: Current state data for production process

• Future State Map

The use of this current state map by lean principle results several modification to the current process. Some of the modifications are: Safety stock, Eliminating Redundant Scheduler and Revising Setup Sheet.

Research Onion

Research onion is depicted as a tool of the methodology that can help in listing the key divisions of any research that has the ability to successfully analyze the topic (Alvesson & Sandberg, 2013). In 2009, Ellis and Levy explained that the research onion as a tool is helpful for academic students. This by following each stage of techniques conducts the research process in a proper format, which helps in deriving results of the research process. The Research onion has been categorized in six main divisions: strategies, approaches, time horizons, choices, techniques, philosophies and procedures. The nature of reality is dealt by Ontological philosophy and this requires researchers to think about how the world operates and how the society should be constructed further. Ontology hence talks about the difference of reality, people’s perception of reality and the technique by how the techniques influence people’s behavior (Chandra & Sharma, 2013). There are total three kinds of philosophical positions: objectivism, constructivism and pragmatism. Epistemology deals with the addresses the factors by asking the definition of acceptable knowledge. This is mostly used in scientific researches which search for facts and information which are proved without any doubt instead of changing the opinions and situations. Axiology let the researcher understand and identify the role of the value and the opinions in the collection of the selected research along with the analysis that has been made to balance the influence.

As illustrated in the above figure, in study of layer of research techniques the research onion can be used, this will enable the better research and collect more information for the analysis of the results. A researcher always needs to follow the layer of research onion such that a structured procedure can be adopted for the further research process (Chandra & Sharma, 2013).

Research Philosophy

As per some conducted research in the past, researchers have commented based on real facts research philosophy is greatly helpful since it helps in gathering the significant information and the knowledge. Several different aspects related to the research work is defined in the Realism Research Philosophy. This philosophy is a mixture of the Positivism and Interpretivism Research philosophy. Positivism is known as the philosophical theory stating the positive knowledge based on the natural phenomenon, properties and relationships. It holds the valid knowledge that are eventually authentic that allows verification (Harrison & Reilly, 2011). Although dominated by some scientific methods, positivism attempts to reject metaphysics such that detailed knowledge and observation collection is enabled. Interpretivism enables the mode of epistemology supports the concept of complex structure involvement of the social world of business and also management activities. Interpretivism involves the researchers to make an interpretation on the elements of the research study (Novikov & Novikov, 2013). Interpretivist philosophical development is based on the critique of idealism and is used to group together the diverse approach.

Literature Review

In this research study, researcher adopts the Realism Research Philosophy since the entire work is based on the socio-culture and political aspects, which means highly significant information are the major necessity for conducting the research. Henceforth, the researchers took the research philosophy for conducting this research (Salaberry & Comajoan, 2013).

Research Approach

As opined by Chandra and Sharma (2013), Research Approach is able to define the entire planning as well as process for executing the entire research work appropriately from start to end in some cohesive manner. On the other hand, as revealed by some practical experiment there are two kinds of research approach that can be done for the conducting any research work. Those approaches are Inductive Reacher approach and Deductive research approach. Inductive research approach refers to observe and identify the data and information along with proper analysis. And the destructive approach refers to develop proper research hypothesis as per the pre-existing theories that are related to the research topic. However, Finn et al. (2000) pointed that for any topic the inductive approach can serve the purpose of a new theory building. Conversely, as a process the deductive approach is used that can describe the practical application of the theoretical study to can gain access to contents of any research paper. Deductive approach hence aims to build a theory with concepts of data analysis and more specifications.

In this particular research study, “Value Stream Mapping in Lean manufacturing”, the researcher have to choose the Inductive Approach because the entire research study depend on the Secondary data that is journal, article, newspapers and relevant books to the topic.

Research Design

The research design are provided suitable comprehensive framework for conducting the research study as well as research designs are able to describe briefly the workflow that is another important necessity for conducting the research study. Three kinds of research design are: Exploratory Research Design, Explanatory Research Design and Destructive Research Design. It is necessary to mention that Exploratory Research design is used while the issue related to the research is not properly explained (Novikov & Novikov, 2013). Exploratory Research Design is used for establishing the brief ideas along with several cause and effects of the research issue (Uprichard, 2013). However, Descriptive Research Design can briefly describe the relationship and the situation as well.

In this research study, “Value Stream Mapping in Lean Manufacturing”, the researcher must choose the Descriptive Research Design because this particular research design is able to help for the description of the situation of the need of value stream mapping for the development and implementation of Lean Manufacturing.

Data Collection Process

In 2006, Veal explained that the data collection enables standard formats of research work that helps in the derivation of accurate result in the research paper process. Data generally considered as some useful collection of raw information and facts that can help in the study of any research topic giving better details about it.

Data Source: Primary and Secondary

Data sources are quiet helpful for penetrating the research topic and thus makes easier for the extraction of information as per the requirement. Data sources have two main category the Primary and the Secondary data source which can provide materials and thus helps in gaining information on the research topic.  In 2000, Gommet al. explains the primary data source as helpful for collection of raw materials which directly could be catered understanding the needs of the topic. The clarification of validity and reliability is generally needed in the first hand data collection, whereas in secondary sources, the data are used to widen the concept of the research topic. This enables for better study and involvement of more data and description of the research topic.

Data technique: Qualitative and Quantitative

For better detailing of the topic to be researched the Qualitative data can be helpful in recording narrative form of data. On the other hand Quantitative data applies, statistical data that proves to be essential in data recording of large sample sizes. The researcher gathers highly important data and information from various sources on conducting this research “Value Stream Mapping in Lean Manufacturing”. The vital data, as well as the information will be gathered from the various relevant journals, websites, books, newspaper and theories. In addition, concentrating on the brief news that are related to the lean manufacturing process in an organization and the importance of value stream mapping for the process of development in the industry and depleting wastes entirely from the environment.

This will be done by the researcher properly for conducting this research study in a cohesive manner. In the above diagram the process of value stream management has been described: First the Value stream mapping has been done, then comes the next step of value stream designing and then comes the value stream planning. Sample considered for the study of Value Stream Mapping and the development in Lean Manufacturing and how this study/practice drops its impact on the customers’ decision making and on the depletion of waste from the environment. The customer’s sample is simple and a random probability sampling where there is no criterion for selection that is to be considered. The sample size is hence divided into two states: qualitative and quantitative technique.

Ethical Consideration

The researcher needs to follow a particular code of conduct during the process of research methodology, that helps in identifying the right and the wrong sets of behavior which is required to be adopted during the process. The researcher for analyzing the role of value stream mapping in lean manufacturing tries to follow few ethical considerations that may help in gaining standardization to the given research topic.

The researcher will remain attentive to all the social aspects and values for conducting the entire study. It is necessary to mention that, they will also be spending the effort hardly to fetch the better information and data from the secondary data collection process. Additionally, the research will frequently gather the updates that are related to the Value mapping providing the updated information within this area of study. As per the “Data Protection Act 1998” the researcher will maintain all the legislative regulations for conducting this research study, along with the highly significant ethics and integrity for ensuring, that the fetched data and information will not be used for commercial purpose. Therefore, the ethical consideration should always maintain the Humanity, Respect, Curiosity, Transparency, Pursuit for perfection, Customer value, Flow/waste elimination, In time, Visual management and working standards within the organization.

Limitations of the Study

Throughout the entire research study, the researcher will conduct this area of study with utmost care. However, due too few limitations, there can be some gap. It is hence necessary to mention that, time can be a major factor and limitation of time for this particular research study because vast knowledge is fetched as well as revenant data and information takes much time consumption. On the other hand, since this research study is based on the development process and how lean manufacturing can be implemented by using value stream mapping in the environment so no targeted population is selected. Thus, the researcher will be facing a few issues that can be contrary regarding the management and maintenance process of lean manufacturing in the manufacturing industry and how they can be used to deplete the waste.

Main project activities or stages	Week 1	Week 2	Week 3	Week 4	Week 5	Week 6	Week 7	Week 8
1. Selection of Research Domain	ü
2. Background Study	ü
3. Selection of Topic	ü
4. Creation of a layout of the entire research work Data collection from secondary sources		ü
5. Existing Literature Review		ü
6. Developing the research plan		ü	ü	ü
7. Selecting   the research methodology to be utilized			ü	ü
8. Conducting Survey (Secondary data collection)				ü	ü
9. Data analysis					ü
10. Data interpretation					ü
11. Concluding the study						ü
12. Documenting a rough draft  of the dissertation				ü	ü	ü	ü
13. Final documentation						ü	ü	ü
14. Final submission						ü		ü

In this particular discussion of the result chapter, the research will discuss the outcomes of this entire research study. As per the basis of the secondary data, the researcher is able to draw a suitable depth analysis on the research topic “Value Stream Mapping in Lean manufacturing”. Value Stream Mapping has the tendency of uncovering waste in products, manufacturing and business process just by identifying and removing the non value adding wastes. It is a common method of recovering a production path. By eliminating the wastes the system is improves the operational procedure and productivity (MohdYusof, Mat Saman&Kasava, 2013). Current state map hence prepared and analyzed to suggest the improvement in the operational process. And according to the future state map the present study graph is drawn to know the improvement of near future (Nallusamy, 2016). In addition, the entire discussion is based on the secondary analysis that is satisfied by conducting this particular research study is included in this chapter for analyzing the justification of the proved secondary analysis.

Theme 1: VSM Methodologies used in manufacturing organizations

Value Stream Mapping are used for sustainable system development in a production industry that addresses and identifies the issues in the value stream, to plan and implement a lean value-stream and improvement project to achieve the sustainable gains, identifying the anticipation improvement in performance and communication technique to leadership that secures the alignment (Mostafa, Dumrak&Soltan, 2015) . The methodologies are compact and simple:

• Firstly to know the fundamentals of the lean thinking and the value stream of the industry,
• Second to identify the non-production value stream wastes which are of total 7 types,
• Third is the key stake holders and the participant of the implementation team  scoping the improvement if the value stream project,
• Fourth is to draw a current-state map and understanding as well as analyze the map and the techniques that support the transformation.
• Fifth is to identify the necessary changes need to develop the future-state map with the current-state map,
• Sixth is using the lean tools and hence develop a future-state map that can identify and address the problems regarding lean manufacturing,
• Seventh is to Plan, implement and manage value-stream.

Theme 2: Current uses of the VSM in lean manufacturing

VSM is considered as the visual means that can be depicted and to improved the flow of production and manufacturing process and the information that can control the flow of materials throughout the process (Mostafa, Dumrak&Soltan, 2015). It a generally the most preferred methodology to identify the wastes in the industry. Thus VSM is used as a management tool in several purposes:

The flow of the materials are analyzed, graphically illustrated and identified the information that is needed to process them. Process map are limited for the mapping of sequence of the tasks which are executed to complete the procedure of value stream mapping that are provided to them (Rohana et al., 2013).  The work is to display the interaction of multiple functions within the process of manufacturing and provide some necessary support to the operation of the industry or some primary activities like scheduling, production planning and material managements (Oberhausen &Plapper, 2015). The communication flow and materials throughout the complete production or manufacturing process coordinates are some common source of significant loss in too many plants. VMS provides the technology or way to visualize and recognize the limited factors.

• Highlighting the problem, inefficiency and loss within the complex system is a common issue as well. Since VMS integrates the material flow as well as the integrated system, and even the sequence of the tasks that includes cycle time and lag between the tasks which has the ability to identify the restrictions limits effectiveness and efficiency in greater enhancement.
• For some cultural changes within the organizations the development and implementation countermeasure is highly effective way. The value stream mapping process on whole utilizes the graphical depiction of the limited factors which all the stake holders visualize very easily (Paranitharan et al.,2014). To actively involve all the stakeholders in each step of value stream mapping this process has been designed.
• The upper management and supervisors always focus directly on the Lean transformation team for the continuous improvement and development in the manufacturing industry (Rahani& al-Ashraf, 2012).
• This is served as the dashboard to the monitor and hence continuously improves the process.

Theme 3: Pros and Cons of the VSM in lean manufacturing at the present era

Advantages of Value stream mapping

Value stream mapping is used for the planning and estimation of the process flow of the lean management. This process is the outline of the whole system that basically finds out the respective steps of the process in predefined order (Oberhausen &Plapper, 2015). The value stream management method has many advantages that make the production or the process well executed. This method of value stream mapping has the following advantages.

• Value stream mapping makes the whole system transparent. This method helps to identify the problems regarding the lean management. The main importance of the value stream management is that it defines all the steps regarding the process so that it can be well executed (Patel, Chauhan & Trivedi, 2015).
• Value stream mapping makes the time duration of the steps and the order of the steps in order to make the project well executed. In this process it can estimate the total duration of the project.
• Different symbols are used in the value stream management process to understand different stages and processes regarding the lean management. With the help of the symbols the big project can be easily utilised in the proper way.
• Another advantage of the value stream management is that it helps to understand about the requirements of the customers and thus make the project in such a way that it can fulfil the demands of them.
• It can help to execute the whole process in a better way by supplying information regarding the process. The information flow is very useful in case of the process execution.

Challenges of Value stream management

Value stream mapping has some challenges regarding the lean management. This method has many disadvantages which should be overcome in order to make the process in well executed way. These challenges and the disadvantages are given following.

• The map sometimes does not contain specific actions for the project. The steps must be specific and should be given with information to overcome the situation. The steps must be well defined in order to understand the process in correct way.
• The symbols used for the steps of the process are sometime not specific. Those symbols are also sometimes not transparent in nature.
• The process steps are also not in correct order sometimes. As a result the project can be lead in a wrong way (Patel, Chauhan & Trivedi, 2015).
• This map has some particular challenges regarding the cost estimation. It cannot estimate the whole cost of the process and thus it can lead to some wrong calculation of the system.

Conclusion

Methodologies of the Lean manufacturing are implemented by the industries having intension to achieve the competitive advantage and business sustainability. In the industrial studies on the implementation and analysis of the lean tool Value Stream Mapping are aimed for the reducing of wastes and hence, increases the efficiency, quantity and quality of the process of production. The production process of industry is considered in the case study, was studied initially through the data collection and analysis. The definition of the initial state resulting information led to the identification and analysis of the critical points. Later, a future state was mapped with a considerable waste reduction and representing a production process which is balanced. To figure out the expected profit of the proposed changes the analysis was performed. The Cycle Time on the assembly sub-process was reduced, the numbers of operators were reduced as well and the inventory level of certain unfinished product has also got decreased. Lean wastes were identified and some solutions were proposed to eliminate them, of which several were implemented. Hence, implementing the action plan, the resulting production system has become functional and effective. The results achieved from the case studies, suggests that from the action plan of remaining solutions may lead the production process to the proposed state and therefore be implemented. Closely monitoring the referred lean metrics should also be continued and the Value Stream Mapping tools can be applied to the complete value chain and to other processes in the industry. The implementation of the Value Stream Mapping is described here is vital for the reduction of wastes and to increase the productivity in the process study, hence providing reasonable evidence to the potential of this lean tool. It is said to be valuable for researchers on the impact of lean thinking in manufacturing, as for implement lean tools, particularly Value Stream Mapping in Lean Manufacturing.

The researcher help identifying the linking obtained between the practical applications and the objectives based on the data collection process. The researcher has tried to link the relatable data such that credibility and rate of success in the study can be improvised as per objectives of the research study. The objectives are hence displayed in the following section as:

Linking Objective 1: Unrealistic Demand from customers

With the increase of highly technological approach in the manufacturing field, the demands of the customers are also getting higher. Sometimes this higher expectation leads to unrealistic terms. To start off a new customer relationship, managing expectations of customer is the most important aspect. It is something that should be done immediately from the outset and if not done In fact, it is easy to make an argument that managing the customer expectations is the most important factor of sales success. It all amounts to define the service criteria and is not as difficult as it might seem. The rate of unrealistic demand is increasing rapidly due to the unaware facts and misconception of lean manufacturing.

Linking Objective 2: Expectations of customers

As observed in literature review customers expect a certain level of service without the idea of having same kind of service everywhere. When it comes to manage customer’s expectations, it is important to get the things right to when the business meets some new customers. Hence, to impress the customers, create a brand for the future development and meet the expectation of the customers is important for any business.

Linking Objective 3: Expectation of top-management

As observed in literature review the top management always expects the best from the employees. A lean manager hence focuses on people. While changing the outcomes when implementing lean tools, may seem like the ultimate goal its people who need to change. This is always a difficult change to bring about the change than to change a process or procedure. The lean manager’s role is to clearly define a goal and hence challenge people to achieve it and give a motivation as well.

Linking Objective 4: Inventory Management methods

As discussed earlier there are five principles of lean management, its ultimate goal is to reach the ultimate goal that is the efficiency. Value: It deals with the area of organizational gain in the lean manufacturing. Flow: It is the flow of product from manufacturing to delivering to the customers. It focuses on the demand-based pull flow. Pull: The only time to pull inventory is when the customer request to. It helps to cut down the excess inventory flow and market trends. Responsiveness: To avoid risk and adopt the inventory behavior. Perfection: It is essential to develop the technique as well as the process to implement methodologies and this needs perfection, which may need some time. Initially it is not that easy and possible. But improvement has to be rapid.  

Project implementation using Lean Six Sigma has eight steps within it:

• Create a Burning Platform

A continuous improvement initiative is implemented while a burning platform is made. The company leaderships should be gaining knowledge related to the burning platform and identify how lean manufacturing can identify the problems regarding this platform. Lack of ideas in people and even developers can lead to destruction of common vision. No common shared vision of an industry amongst the leadership. 

• Put Resource in place

The knowledge of potential resource is important as well as essential for an organization. The effective knowledge centers are intended to accomplish the task. It is becoming a major management focusing and involving a range of industrial, informational and behavioral challenge.  Thus getting knowledge, products and ideas applications are most cost effective and are in timely manner.

• Teach the methodology

The organization need to learn the various methodologies and increase awareness within the employees

• Prioritize Activities

Industries must make this as their major priority is to listen to the customer and hence identify the critical-to-quality criteria. Ensuring the effort of Lean Six Sigma that are linked to other business goals.

• Establish Ownership

This may involve appointing a committee to find out who is responsible for the entire team. The effective knowledge centers are intended to accomplish the task. Empowerment comes with ownership and the senses of pride so the team members who are much accountable, committed and engaged come within. It is becoming a major management focusing and involving a range of industrial, informational and behavioral challenge. Thus getting knowledge, products and ideas applications are most cost effective and are in timely manner.

• Take the right measurement

For getting the right cost of the quality, this is the key for measurement. Organizations should find a way to measure process performance that ensures for them to receive data at a faster. On a scorecard having too many items may shift practitioner’s attention from the few critical metrics. These are needed to be identified and measure for the lagging indicators. The non linear behavior of manufacturing industry can lead to decrease in the number of consumer depending on the lean.

• Govern the program

The program sustain momentum can be helped by a proper governance structure. Too much governance of poor governance can lead to the vision falling apart. Establish a business quality council that can help in cleaning any hurdles which may establish a business quality council and allow the project work from adheres to timelines.

• Recognize Contributions

To make the team members remain satisfied in their roles the Rewards and recognition play a very valuable role. Rewards and recognition also can help drive innovation throughout the organization. They can also help in building enthusiasm for the program from a top-down and grassroots level.

Recommendation for lean management to make a lean manufacturing project more successful in terms of the reduction of wastes and more recycled production the following steps are recommended. To make a successful lean manufacturing formation of a proper team is important. The team should contain people having enough experience and knowledge in the business and lean management industry.

• It is important to make the strategy for the development and proper communication in the whole process. Feedback is an important part in case of management and thus it should be taken care of in every step of the process.
• The communication with the employees should be done in a proper manner to make them understand about the strategies and the business principles of the company. They should be suggested to focus more on gathering idea and information. The organisation as well as the individual goals should be explained properly to the employees.
• Making a perfect value stream mapping is the most important part for the whole lean management .Value stream mapping is the initial part of lean manufacturing. It defines the outline of the whole process. From collecting the material to finalising the whole product, value stream mapping defines all the steps regarding the process. It is more like a flow chart of the process. It is important to make the value stream mapping in a correct order to finalize the project in a successful and well defined manner. Value stream making helps to analyze the process and to find different aspects of the production. The manufacturing of the products depends upon the steps and the order of the value stream mapping. Here is some recommendation for the value stream mapping of lean management.
• The value stream mapping depends upon the product that has to be recycled and the properties of the waste.
• Value string mapping is consisted with many symbols that define various steps related to the lean management. These symbols are to be used in a scientific manner and should be utilised with respect to the predefined regulations. It should be in a well structured way so that the process is executed in correct manner. At the same time it should be transparent as people working in the plant should easily understand the symbols used in the value string mapping.
• There are many boundaries and difficulties in lean management. Those should be well defined at the time of value stream mapping.
• At the time of designing the value stream mapping the information should be given with respect to the corresponding process. The flow of information should be in correct order to make the process easier to understand.
• Calculating the timeline and the duration in case of value stream mapping is an important step to be followed. The execution of the whole process depends upon the time duration given for each of the steps.
• In the time of value stream mapping the requirements from the customers should be maintained well and must be given highest priority.
• Finally the process should be finalised with the help of 5S technique that follows five steps which are sort, set in order, shine, standardize and sustain.

The paper fulfils some research gaps by investigating the impact and relationship on the most essential and important implementation of value stream mapping in lean manufacturing which has some contemporary measurement on the operational behavior of the manufacturing industry like the depletion of waste materials. Several constraints were encounter with circumstances which are essential to highlight in order for some similar future studies and bring them into consideration. The survey of questionnaire software has restrictions to access from other industry’s internet browsers. It is still on count how many industries got affected by the problem, but it has been assumed that the corporate restrictions within industries were particularly large organization has imposed tougher access to external websites linkers, and to increase the questionnaire’s response rate there was in-fact a barrier. Due to the issues considering the encounter with internet restrictions, it could be proved profitable to send out some number of questionnaires by post for the future studies. In the other hand, carrying out interviews would increase the rates of response; such methods are constrained by resources like the time and capital. Although the rate of response which is obtained and used for the analysis is comparable to other similar studies, it is considered as limited. Therefore, some similar studies conducted by using a higher rate of response that are considered as a part of the agenda for further research proposed in this discussion. Value Stream Mapping is a very crucial tool of the lean approach and are generally used to identify the value-adding activities and wasteful of the materials and the flow of information and people in the industry. But the value steam mapping in lean manufacturing has several limitations like the mapping process does not begin to capture all the specific action that is the originators that are applied to the product families. Uncertainly in a value stream mapping analysis can lead to supply chain risk so it is suggestible to identify the product family first, addition of random aspects of value stream in the corresponding function, etc.

To further develop in Value Stream Mapping in Lean Manufacturing, the research must be carried out with a consideration on not only the manufacturing industry, as it is the topic for this research, but also on other industries in which the lean strategy can be beneficial as well. Moreover, considering the importance that many society, industries and governments in general are paying attention on the ‘green industry’ and the sustainable area, the impact of lean methods and tools can also be explored in relation to these two aspects. The mixed method of approach involves the quantitative and qualitative data-sets cam be followed by the future empirical studies which can be experimented through some rigorous statistical methods, including the conduction of a non-response bias test. To ensure the higher confidence of the data collected some higher rate of response and some mixed quantitative–qualitative approach with more strong statistical analysis method may allow the generalization of the findings in similar studies. The waste counter measure should be following some major points like standard work, quality of the source, visuals, pull system, cells, level loading, batch size reduction, work balancing, set up, changeover reduction, work segmentation, automation, cross training and multi-functional worker. Finally, considering company size, length of time of the lean initiative and industrial sector, the analysis of results could be carried out drawing conclusions and outcome from some more specific view point.

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