Lean manufacturing in a mass customization plant : improved efficiencies in raw material presentation

Abstract

This thesis focuses on the application of the principles of lean manufacturing at Varian Semiconductor Equipment Associates (VSEA). The company faces the challenges of highly customized assembly as well as fluctuating demand, both of which cause lead times that are longer than expected. Value Stream Mapping was used to identify the main sources of waste in the VSEA manufacturing plant. After evaluating all factors contributing to longer cycle times, it was found that one of the main problems encountered by VSEA was unorganized presentation of raw material to the shop floor. Using the 5S methodology, a framework was created to appropriately categorize the raw material into smaller groups, and deliver them to the flow line according to Just-in-Time (JIT) principles. After the new presentation method for raw material is implemented, the cycle time will be reduced by 6% due to the elimination of the non value added activity from the process. In addition, the first steps toward kaizen process improvement will be in place.