Optimization of Process Flow in an Assembly Line of Manufacturing Unit through Lean Tools Execution

The main aim of this study is to achieve the maximum productivity in an assembly line of a valve manufacturing industry through the implementation of different lean tools to minimize the production time. The existing manufacturing data were collected and interpret the information’s for identifying the gaps for productivity improvement. For obtaining the production line performance we shall introduce a solution after finding the problemswhich affects the lead time. In this research, an attempt was made to introduce a new fixture with appropriate lean methods by focusing on value stream mapping, kaizen etc to eliminate different kinds of lead times consuming phases in the overall process. Designing a fixture for the process is also done in Kaizen, in order to exclude the sub operations. After execution of various lean tools the total cycle time was reduced about 10.49 minutes and the productivity was improved about 20% by eliminating all those non value added activities in the operations to meet the customer demand.