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This study is an attempt to develop a decision support and control structure based on fuzzy logic for deployment of automotive airbags. Airbags, though an additional safety feature in vehicles, have proven to be fatal at various instances. Most of these casualties could have been avoided by using seat belts in the intended manner that is, as a primary restraint system. Fatalities can be prevented by induction of smart systems which can sense the presence and differentiate between passengers and conditions prevailing at a particular instant. Fuzzy based decision making has found widespread use due to its ability to accept non-binary or grey data and compute a reliable output. Smart airbags also allow the Airbag Control Unit to control inflation speed depending on instantaneous conditions.

This research is an attempt to investigate the significance of Value Stream Mapping (VSM) in the lean transformation of manufacturing units (largely automotive) and then apply the same in a tool room. It is an essential tool used to interpret both material and information flow in a system. The tool room under study specializes in production of a large variety of high precision tools for the automotive industry. A product family is chosen to map and analyze various stages of its production process, starting from the raw material (R/M) to the finished goods’ (F/G) stage. VSM is then implemented in the tool room to correctly identify wastes and thus improvement areas to bridge gaps between current and future states. Both current and future state maps are drafted along with usage of other lean tools to justify its implementation in a small setup like tool room.