Integration of value stream mapping with Taguchi’s orthogonal array to improve productivity and quality: A case study of SSE

Abstract

Abstract The purpose of this article is to illustrate the application of the lean manufacturing practice and statistical techniques to achieve overall excellence in small scale enterprise (SSE). Researchers have reported this article through the integration of value stream mapping (VSM) with Taguchi s orthogonal array. VSM helps to give a broad overview of the entire process, while the orthogonal array helps to optimize process variables. Researchers have identified long waiting time at the melting department for molten pouring and excessive mould rework. Expert opinion and brainstorming are used to collect qualitative opinion for furnace efficiency improvement. The levels of the process parameters for mould rework - binder addition, CO2 pressure, mixing time and sand weight are optimized with Taguchi s S/N ratio. As a result, the waiting time and mould rework are reduced by 90\u202fmin and 31.72% respectively. Analysis of variance is used to determine the statistical significance of process parameters.