Lean manufacturing implementation with value stream mapping methodology in a manufacturing company

This study presents a case study aimed at the elimination of waste and the enhancement of productivity in manufacturing processes, in line with lean production principles. Within this scope, an initial implementation for the transition to lean manufacturing was carried out at a truck axle production facility in Konya, utilizing the value stream mapping methodology. The application began with an analysis of the company's current state, visualizing all value-added and non-value-added activities in the production flow. This analysis clearly identified fundamental wastes such as unnecessary waiting times, inventory, and transportation. Based on the current state map, a future state map was designed to eliminate these wastes and optimize the flow. The implemented improvements resulted in significant gains. The duration of non-value-added activities was reduced by 39.5%, while the total flow time decreased by 36.8%, from 1276 to 806 minutes. A product design update achieved a 12 kg weight reduction and a 4% decrease in semi-finished material costs. Time reductions were also realized in processes such as welding, cleaning, and assembly. Furthermore, through the integration of lean tools like 5S, a supermarket system, and a pull system, transportation distances were reduced by 72% and forklift trips by 75%. This study demonstrates the effectiveness of Value Stream Mapping in achieving multifaceted and substantial productivity increases within manufacturing processes.