Assessment of implementation of lean manufacturing in manufacturing unit - a case study

Abstract

Lean manufacturing is a performance-based strategy for maximising customer value by elimination of waste, while improving profitable growth of the organisation. The present study has been carried out at recliner assembly shop of an automobile manufacturing industry in North India with an aim to develop and implement lean manufacturing program in a systematic manner. The systematic procedure has been adopted to identify wastes, their reasons of occurrence and selection of suitable methods adopted for their removal. The recommendations of experts have been implemented by conducting a tack time study of recliner assembly process which reduced inventory by 14% by line balancing. The divisions of customer s monthly requirements into week plans has improved the tool setup time by 29% and reduced working delay. Administrative controls have been implemented to conduct in house training sessions of workers that had reduced absenteeism by 15%.