Lean Manufacturing Practices Assessment Case Study of Automotive Company (original) (raw)
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Evaluation of Lean Manufacturing Practices in an Automotive Component Manufacturer
Revista Gestão da Produção Operações e Sistemas
Purpose: This study aims to evaluate lean manufacturing (LM) practices used in a company in the automotive component industry located in Polo Industrial de Manaus (PIM), a manufacturing hub in the city of Manaus. Theoretical framework: The AME Lean Assessment instrument was used as the research framework in this study. This instrument was developed by the Association for Manufacturing Excellence (AME) to benchmark where a company is on its lean journey. Design/methodology/approach: An exploratory case study was carried out, and since a more detailed study was needed, a research framework was used, composed of 14 attributes on lean manufacturing. Findings: The findings point to a high level of LM practices adopted by the company, in addition to allowing the practical application of the fundamental concepts to be observed for the Toyota Production System (TPS) at Polo Industrial de Manaus. The findings have increased the understanding in organizational behavior relating to LM. Researc...
The manufacturing sector, considered to be an important industry in any country, is often plagued with a significant degree of competition due to global marketing. In order to cope with this challenge, organisations attempt to improve their manufacturing operations by using different tools and techniques to reduce costs while remaining profitable. This study investigated the existing lean production system of an automotive manufacturing organisation in Durban. The objective of the study was to identify the strengths and weaknesses of the current lean manufacturing process in an attempt to improve quality and productivity. An empirical study was conducted, using a survey questionnaire with an assessment score ranking to gather and evaluate employees’ responses pertaining to lean application in the production environment. The quantitative method of research was adopted. The results of the study showed evidence of misalignment and inconsistencies for lean adoption in the organisation. ...
A STUDY ON LEAN MANUFACTURING IMPLEMENTATION IN MALAYSIAN AUTOMOTIVE COMPONENT INDUSTRY
Lean manufacturing is an extended version of the Toyota Production System (TPS). It was highlighted as the best practice in the 21st century. Therefore, top and senior management in manufacturing firms are encouraged to adopt and adapt lean principles and practices in running their respective firms. The main objective of this paper is to investigate the extent of lean manufacturing perception and implementation in the Malaysian automotive component industry. A survey questionnaire was developed to collect top and senior management views with respect to their perception, judgement and opinion on twenty four lean manufacturing (LM) practices. This preliminary survey was conducted at 30 Malaysian automotive component manufacturing firms. The survey results show that a large majority of respondents have a high perception of the importance of lean manufacturing practices. However, it was found that their actual LM implementation is still on the low side. In this study, the non-parametric test was used to analyze the level of perception and implementation of the twenty four LM practices. The analysis of the survey results revealed that there are significant differences between the level of perception of the importance of LM practices and their actual implementation.
Due to global competition, automotive component industries are very keen to improve their manufacturing system as to fulfill car manufacturer demand. Currently, lean manufacturing (LM) system has become increasingly famous and popular among automotive component players. And, it was proven that lean manufacturing is the best manufacturing system in the 21 st century. The main objective of this paper is to investigate the extent of 24 lean manufacturing practices implementation in SME. Secondly, to determine the possible barriers that could influence the process of lean manufacturing implementation. A survey questionnaire was developed to collect top and senior management judgement on 24 lean manufacturing practices and to rate the possible barriers during lean manufacturing implementation. Total completed questionnaires were 97 which represent 81.5% respond rate. The survey results show that a majority of respondents agreed and implementing extensively kaizen, 5S and standardization in their firms. Another finding was the four possible barriers that could influence the failure of lean manufacturing implementation which are employees resist to changes, unstable customer schedule, lack of knowledge and poor employee involvement.
Lean Manufacturing Practices - a Literature Review
International Journal of Advance Engineering and Research Development
Survival of any industry in this era of globalization & a cut-throat competition becomes extremely difficult. In order to survive, it is necessary to adapt to this ever changing environment. Globalization has made this competition fierce & has also helped in developing techniques & methods that are exceedingly helpful for any industry to flourish even in today's times. Lean is one such tool that can be applied anywhere & everywhere in industry. From shop-floor to the top management, lean has proved its mettle. Application of lean reduces the wastes that are produced & also helps in streamlining the production system. It focuses on continuous improvement & at the same time reducing the wastage. Widely used techniques like Kaizen, 5S, Six Sigma, Value Stream Mapping (VSM) are a part of lean. Implementation of lean leads to all around development of any industry. This paper discusses comprehensive literature on implementation of lean manufacturing. The case studies considered in this paper includes work of international researchers.
International Journal of Engineering Research and Technology (IJERT), 2012
https://www.ijert.org/strategies-for-the-successful-lean-manufacturing-implementation-a-case-study-in-a-malaysian-automotive-parts-manufacturing https://www.ijert.org/research/strategies-for-the-successful-lean-manufacturing-implementation-a-case-study-in-a-malaysian-automotive-parts-manufacturing-IJERTV1IS9015.pdf In recent global business environment, many manufacturing companies are attempting to implement lean manufacturing system. Malaysian manufacturing companies are no exception, and they consider lean manufacturing as an effective manufacturing strategy to survive in a highly competitive market. Given the lack of clear guidelines or step-by-step procedure in effectively implementing of lean manufacturing system among Malaysian manufacturing companies, this paper aims to present a case study of a manufacturing company pertaining to the automotive parts manufacturing company in Malaysia which has achieved significant improvement in productivity as a result of successful lean manufacturing implementation. The finding suggests that factors such as continuous management commitment, teamwork, and organization-wide involvement are crucial to lean success. The case study is expected to contribute important implications strategies for lean manufacturing system implementation in Malaysian manufacturing organization.
A Full-Blown Concept of Lean Manufacturing System in Automotive Industry
Journal of Industrial and Intelligent Information
Lean manufacturing system (LMS) is not a novel concept to manufacturing and the automotive industry, but achieved implementations seen are still not considered industry-wide especially in the Malaysian automotive manufacturing industry. The implementation strategies have not been far reaching and the benefits from the system couldn't be gained by the industry. A total and comprehensive implementation strategy of LMS needs to be outlined in order to achieve more successful implementations. Thus this paper will explain the strategy of LMS implementation in the automotive industry by using the full-blown concept, for enhancing their organizational performances. A questionnaire-survey was administered to gauge the impact of these factors in an implementation process of lean manufacturing system and later analyzing the effect towards their organizational performances. Data from 204 automotive parts manufacturers were gathered and analyzed. The correlation between the 10 influencing factors, 5 lean activities and 6 organizational performances were measured. The results gained, suggest that the integration between the identified influencing factors (Management and Leadership Commitment, Employees Involvement, Empowerment of Employee, Teamwork, Training, Human Resource Management, Customer Relationship Management, Supplier Relationships Management, Organizational Change and Information Technology) will be a valuable key organizational capability impacting organizational performances towards the successful implementation of LMS in the Malaysian automotive industry.
IJERT-Implementation of Lean Manufacturing In Automotive Industries
International Journal of Engineering Research and Technology (IJERT), 2021
https://www.ijert.org/implementation-of-lean-manufacturing-in-automotive-industries https://www.ijert.org/research/implementation-of-lean-manufacturing-in-automotive-industries-IJERTCONV9IS10018.pdf In the Internet world, automotive manufacturing and process industries face the challenge of a highly dynamic and interactive business environment. Industries that have traditionally delivered manufactured goods must streamline their processes and focus on the rapidly changing needs of their customers and the capabilities of their suppliers. Now, more than ever, the capability to deliver quality, cost-effective products determines the success of the world's automotive manufacturing and process industries. The variety of motor vehicles is expanding and the market is no longer dominated by a handful of very high volume automobiles. The automakers have been able to respond much more quickly to this demand for a range of models with the adoption of lean production. One of the most critical issues for the automotive industry today is competitiveness in cost, quality, and product offerings. Companies cannot survive in today's market if they neglect any of these areas. Lean is one of the promising alternative strategy for achieving continuous improvement in business performance through identifying a company's value stream and then systematically removing all waste. The implementation of lean management principles in automotive industries can increase efficiency, reduce project costs and also reduce revenues. Given the current pressure on product margins, lean manufacturing principles provide an excellent framework for squeezing costs out of manufacturing.
Implementation of Lean Manufacturing Tools for Improving Productivity: A Case Study
Present research focuses on the quality improvement at Himachal Pradesh based manufacturing unit a precision machining company for two and three wheeler components. The objective of present research focuses on current Quality Management System (QMS) implemented and to identify the current quality problems that the company faces and to study. Present research is divided into two parts Ethnographic and Qualitative research design. Recommendations and solutions to the problem faced will be suggested to the heads and supervisors, to improve the current quality system, as well as increase efficiency and reduce non conformities. This research only focuses on problem faced in the production section of the company. In the ethnographic part study is focused on plunging of workers and qualitative part research is focused on various causes of rejection. Lean manufacturing tools is considered as the pilot project to solve the problem. Various tools were used such as Multiple activity charts, Pareto chart, PDCA cycles, cause and effect diagram and control chart. With the help of lean tools, plunging of workers come to zero, better working environment is provided to workers, rejection has reduced o 12000ppm from 29000ppm and reduced the loss of organization from 4.02% to 2.79%. Retention of worker saves the training cost. Tool life also increased.
Implementation of Lean Manufacturing: A Case Study at ASK Automotive Private Limited (India
Lean manufacturing is a known principle used in today's industries to eliminate various hidden wastes that do not add value to the finish product. Lean concept has many advantages which have helped many companies over the years to stay more competitive in global and national business. The purpose of this study is to develop a value stream map for ASK Automotive Private Limited, Manesar in Gurgaon, how information is distributed across the entire company from raw material finished goods suppliers to the customers. This particular tool allows the company to document current lead time, inventory levels and cycle times to determine the ratio of value added to total lead time of the product line being analyzed. Interviews have been conducted with various distribution centre managers, raw material suppliers, and also technicians to familiarize with how things are done currently and the way forward to achieve the aim of operating on lean. Operators and other staffs will be trained to understand how lean works and also the need for continuous improvement and not just a onetime improvement. Recommendations have been made to enable the company to reach the ultimate aim of operating on lean principle which has been known to be helpful.