Value Stream Map And Theory Of Constraints: A Combined Study Of Lean Application In Automotive Industry

The purpose of this paper aims to improve the traditional VSM(Value Stream Mapping from Lean Production) method combine with the TP-TOC(Theory of Constraints Thinking Process) and TPS(Toyota Production System), also to find a better methodology to apply them in a lean manufacturing system design of an automotive seating plant. The background of this paper is to support the target of company J back to the market leading position through key transformations like production lead time reduction and talent thinking process improvement. The main methodology of this paper: following an introduction of the latest research trend and a combined use of these methods enable a systematic way to analyze, measure and identify the root cause/causes, key constraints, core conflicts and obstacles of the system, take TPS know-how as an injection solution to improve the effectiveness and efficiency. Through Future VSM, Future Reality Tree, benchmark MIFM to support the new plant facility layout redesign, point out the important use of Element Work Linking Sheet together with the critical path design to reduce the internal change over time.The findings of this paper revealed the ineffectiveness, inefficiencies and limitation problem in the traditional VSM method which fails to provide a logical sound thinking process. Identifying the core conflict of(company J) inherent of the past 10 years is the departure of lean talents cultivation low speed and automotive industry growing high speed in China. Pointing out the importance to apply VSM(time dimension) and MIFM(space dimension) into future new plant facility layout designs and preventing potential failures. The originality and value of this paper: combines VSM with TP-TOC and TPS, discusses the history, difference and SWOT analysis, improves the integrity and practicability of the three methodologies. Compares the MIFM in Toyota with VSM, summarizes the reason why Toyota prefer MIFM rather than traditional VSM method since the 1990 s. Compares and summarizes the specialties in Toyota style seat plant facility layout design to support the very short production lead time in TPS.