An interactive value stream mapping tool to support the inefficiencies reduction in manufacturing setting

As nearly one third of the world's energy usage and carbon dioxide emissions stem from manufacturing, it is becoming increasingly vital to cut down on energy and resource usage in industrial settings. Thus, advancing research and innovation for the future of factories is not just about creating and incorporating new technologies, but also about transforming manufacturing to rely less on energy and operate more efficiently. This entails approaching resource usage with a systematic mindset to ensure optimal exploitation. In this context, this paper aims to propose an interactive value stream mapping to evaluate the resource utilization and minimize the defect reduction in manufacturing setting. The efficacy of proposed model is being checked through case example of forging industry. This study emphasis on defect and lead time reduction, results enhancement of production level in forging industry. Moreover, lean tools like process flow chart, SIPOC (Supplier-Input-Process-Output-Customer), and cause & effect diagram were also adopted in this study. The obtained results reveal that defect rate in hot forging is reduced from 1.09 to 0.85, value added (VA) activities increased by 60%, and the non-value added (NVA) activities reduced by 92% significantly in the forging industry. Also, lead time of forged product is reduced from 9 to 5 days. These results underscore the potential for applying such methodologies to optimize processes in turbo-machinery design and production, ultimately contributing to enhanced performance and cost-effectiveness.