VALUE STREAM MAPPING OF YARN AND SEWING THREAD MANUFACTURING PROCESS: A CASE STUDY

Abstract

This thesis intends to identify, investigate and recommend solutions for waste-related problems in the process flow of the dyeing process by utilizing value stream mapping (VSM). The study was initiated by selecting two product families yarn and sewing thread. Time study is done for all the sub-processes of both product families. Then the current value stream maps were formed using the collected data. Then by investigation wastes and other losses were identified. The analysis also shows that the loading and unloading processes for all the sections required a quite long time. The waiting time for machines to be free and time for unnecessary movement also takes much time. Lastly, some improvement proposals were suggested. The measures proposed to reduce wastes include implementing an automated system for package loading and unloading, trained the worker, implementing 5s, etc. The proposed process can help achieve a faster process flow, an organized management system and can help to meet daily customer demand by reducing process time. Value Stream Mapping shows which processes are timeconsuming and so steps can be taken to optimize those processing time.