Analysis of Barriers Value Stream Mapping and Performance Measurement for Lean Implementation in an Electronics Component Manufacturing Organization

Abstract

Lean concepts are being increasingly applied by electronics component manufacturers to enhance product value through streamlined processes. In order to facilitate smooth adoption of lean concepts, barriers need to be analyzed and prioritized. First research module presents the analysis of barriers affecting the adoption of lean concepts to electronics component manufacturing. In this context, a structural model of 24 barriers is developed through total interpretive structural modelling (TISM) approach. Changing governmental policies , poor selection of change agents and improvement teams , lack of top management commitment understanding and support of the system , lack of team autonomy , lack of flexibility and versatility and lack of customer focus / involvement are found to be the dominant barriers based on TISM study. Interpretation statements are being derived from TISM model. MICMAC analysis is being conducted. The second module aims at identifying and prioritizing lean tools to be deployed to improve the operational performance of an electronics component manufacturing organization. This module aims at identifying wastes associated with the process and to prioritize lean improvement proposals to be implemented to attain leanness and facilitate streamlining of the process. Using value stream mapping (VSM), the current state map is constructed, wastes are identified, lean improvement methodologies are identified and deployed in future state. The identified lean tools are prioritized using fuzzy VIKOR technique. Among the suggested improvement proposals, cycle time reduction occupies top position in the priority order. On implementing the improvement proposals, inventory is reduced by 49.14%, cycle time gets reduced by 11.31% and number of operators are reduced by nine numbers. On successful deployment of lean manufacturing tools, it becomes essential to evaluate the leanness level of an organization, as it identifies ill performing criteria and enables organization to explore process from lean.