Application of lean principles to an enterprise value stream : a lean analysis of an automotive fuel system development process

Abstract

This thesis shows that lean principles that have been successfully applied in manufacturing can also be successfully applied across an entire enterprise. Established lean principles and lessons learned in lean manufacturing environments are applied across an automotive fuel system enterprise. This enterprise includes all major activities used in developing and delivering fuel systems to customers from the initiation of the systems concept to final production manufacturing. The value of the enterprise's product (fuel systems) is specified in terms of enterprise customers. The value stream of the fuel system enterprise is identified and analyzed using process mapping, input/output information flow diagrams, and other techniques. Major issues in terms of waiting time, rework time, and excessive need for validation are identified using these techniques. Countermeasures against these issues are offered to facilitate a transition to a leaner state. The goal is to develop a systemic understanding of the fuel system enterprise such that lean principles and tools can be applied to its processes to improve efficiency, throughput, and value for customers. Recommendations for further study are also listed in an effort to pursue perfection by continuously improving the lean enterprise. Finally, a transition to lean implementation plan is outlined.