Application of Value Stream Mapping for Assembly line of Precast Elements

Abstract

In recent years, there has been a paradigm shift in the construction industry toward more streamlined and efficient processes. Precast construction is technology is very advanced and time reducing technique which is now a days used in many projects to eliminate challenges of quality control, delay in construction. In this technique components are made in factory and then transported to construction site and erected at their location, which is very time saver in construction projects. Precast construction technique is following manufacturing sector rules, where certain process are going in cycle by cycle. This manufacturing part also facing issues related to delay in time, over process. Lean principles are popular now a days in construction industry to reduce the waste. So lean concept is one of the best technique to avoid wastes in manufacturing process which will lead to increase in productivity of production, remove wastes and increase value. Lean concepts is basically process improve technique which continuously focus on improve productivity and make it effective as it possible.

This study investigates the use of VSM prinicple to reduce cycle time of pre-cast element assembly lines, an essential part of contemporary construction methods. Lean concepts place a strong emphasis on reducing waste, iterative improvement, and effective resource use. The topic focuses on locating and resolving major issues, like bottlenecks, pointless movements, and overproduction, in the pre-cast element assembly line. Lean techniques will be applied to improve overall productivity, shorten lead times, and streamline workflows through a thorough analysis of the current assembly process. The goal of the study is to provide a systematic framework for implementing Lean concepts in the context of pre-cast element manufacturing. The results of this study will help to improve the pre-cast assembly line that is more responsive and agile, which will eventually improve project schedules, reduce cost, and productivity in the construction sector. Adopting Lean concepts in pre-cast element assembly holds great promise for reaching greater levels of operational excellence and satisfying the expanding need of construction industry continues to change. The research explores the environmental sustainability aspects of Lean practices in pre-cast element assembly,By optimizing resource utilization and minimize waste generation.

Lean tools are methods that increase productivity, cut waste, and improve quality in lean manufacturing and lean management. Three essential tools are Kanban for visual scheduling, Kaizen for continuous improvement, and 5S for maintaining and organizing the workspace. By manufacturing in response to demand, Just-In-Time (JIT) reduces inventory, and Poka-Yoke guards against mistakes. Heijunka facilitates the flow of production, while Root Cause Analysis (5 Whys) pinpoints the underlying problems. Workflow visualization with Value Stream Mapping (VSM).

Value stream mapping (VSM) is one the tool of lean concept which is used to identify and eliminate the waste in process of manufacturing. The main objective of study is to improve the productivity on precast production factory as well as on site construction process. In this paper one real case study has taken of assembly line of whole precast production, from manufacturing to erection of component at construction site. In which VSM tool is applied to make value added output of the project.

This study has revealed a significant opportunity for enhancing the overall efficiency of the precast assembly line by implementing the principles of Value Stream Mapping (VSM) lean methodology. By utilizing VSM, there is a clear path to minimizing the cycle time required for production and enhancing the productivity levels within the work environment. This strategic approach aims to streamline the various processes involved in precast assembly, thus fostering a more agile and resource-efficient operational framework. Through the strategic application of VSM techniques, organizations can uncover potential bottlenecks, identify areas for improvement, and ultimately optimize the entire production workflow. The integration of VSM tools offers a systematic way to visualize the flow of materials, information, and resources throughout the assembly line, thereby fostering a culture of continuous improvement and sustainable growth. By incorporating lean principles into the operational strategies, companies can unlock new levels of efficiency and effectiveness, leading to enhanced output quality and customer satisfaction. In essence, this study underscores the transformative impact that VSM lean tools can have on the precast assembly process, paving the way for enhanced competitiveness and operational excellence in the construction industry.