The Use of Lean Manufacturing Tools to Improve the Production of Automobile Parts (original) (raw)

Study of Lean Manufacturing for Manufacturing of Auto Components

2018

Lean manufacturing is the manufacturing philosophy and the system that was given by the Toyota, Japan and now the many of the manufacturers are using these techniques in industries. "Lean is simply a systematic technique or approach to identify and eliminating the waste through the continuous improvement by flowing the product at the pull of the customer in pursuit of the perfections. The main aim is to eliminate the wastages in every area of the production including the customer relations and the product design and suppliers". Lean tools and approach are very much popular in the automobile component manufacturing which is improving the growth initiatives in the automobile industry in last two decades. In automobile these lean tools like JIST,5S, Six Sigma, FIFO, LIFO, Continuous Improvement, JIS, Kanban processes also helps in the rapid development and growth in assembly line and overall production and growth specially in automobile sector. Nowadays almost 70% to 80% improvement in most of industrial growth is due to the approach of lean manufacturing.

Lean Manufacturing - an Advanced Manufacturing Technique for Auto Industries

2017

With ever shrinking time to market, companies are constantly seeking new ways of producing customized parts cost effectively. Could this be done without resorting to the traditional manufacturing processes? This is the age of new manufacturing. With accelerating technological changes as increasing compactions at both local and global market place, only those companies, which are both flexible and agile, will survive in the future. The dawn of new century begins with it, new rules of competitions, concepts such as supply chain management, flexible manufacturing and lean organizations have become preconditions for companies that seek to compete in the long term. This paper explains about “Lean Manufacturing an Advanced Manufacturing Technique for Auto Industries”. Lean manufacturing system is modern production strategies that uses less resource such as human effort, production space, investment in equipment and machine, time for developing new products and services and performs the pr...

11. Implementaion of lean manufacturing in auto industry

Lean manufacturing is defined as a systematic approach to identifying and eliminating waste through continuous improvement, flowing the product at the pull of the customer in pursuit of perfection. This paper describes some learning from the literature and actual practices in USA, UK, and India. Attempts are made to present the gaps between the principles and practices. Some pertinent propositions are put forth to enrich the knowledge base of professionals to make the implementation process more pragmatic and robust in the long run and for furtherance of empirical research by academics.

Improvement of Production Processes with the Use of Lean Manufacturing Tools

Multidisciplinary Aspects of Production Engineering, 2018

Growing competition, clients’ requirements as well as advances in technology make modern industrial enterprises search for a way of achieving and maintaining strong position on the market. One of the principal and at the same time necessary conditions to achieve this aim is continuous development of all of the processes in order to fulfil various clients’ expectations. Enterprises make use of different concepts and management methods which in significant way upgrade ongoing processes by raising their efficiency. One of such is the concept of ‘lean’ production - Lean Manufacturing. Management according to Lean Management rules allows to produce more with the use of less resources - at the same time approaching the aim which is to deliver clients the exact product they want. The process of resources use limitation is not easy to perform however, the concept of Lean Manufacturing by the application of chosen tools allows successfully and effectively to introduce ‘lean’ model of managem...

Lean manufacturing – results of selected implementation projects

Journal of Intercultural Management, 2013

Lean Manufacturing is a structured program whose objective is to maximize the effectiveness of the company. It is based on the practices and methods of KAIZEN / LEAN applied by the world’s best companies. The experiences from the Author led us to the conclusion that the Lean Manufacturing is based , among others, on the following concepts: - Total Productive Maintenance TPM - Single Minute Exchange Die SMED The Lean Manufacturing focuses on the systematic pursuit and elimination of waste and losses. The losses identified are analyzed, evaluated in adequate manner to the attribute processes. The result of the analysis determines where and how to intervene. In the paper has been presented the bases of Lean Manufacturing. The results of the implementation of Lean Manufacturing in different companies have been described. The main issues of Lean Manufacturing implementation have been characterized.

Lean Manufacturing Practices Assessment Case Study of Automotive Company

Production Engineering Archives

Lean Manufacturing (LM) practices have gained popularity as a means to achieve high-quality products while reducing costs and delivery times. However, the implementation of LM can be challenging, with a high failure rate. This paper aims to explore the perspectives of employees and managers on LM practices implemented in an automotive company. The research involved primary and secondary data analysis, combining observation, interviews, and a questionnaire survey. The survey assessed knowledge and skills, impact on quality improvement, motivation, supervisor support, control, and engagement in LM development. The results highlight the importance of management commitment and support in achieving successful LM implementation. Moreover, the study emphasises the positive impact of LM practices on employee motivation and the overall quality of processes and products. The PDCA cycle emerged as the most impactful tool, along with other recognised tools like Poka Yoke, Andon, Kaizen, Visual ...

Implementation of Lean Methodology on the Main Assembly Line of an Automotive Plant to Enhance Productivity

Journal of ICT, Design, Engineering and Technological Science, 2020

Productivity can be enhanced by reducing wastages in a process while maintaining or increasing the amount of output. This is real work carried out in the automotive industry. In our work, we enhanced the productivity of the assembly line in an automotive plant by applying lean methodologies. There is an extensive range of tools available to remove all kinds of wastes, from which we selected the following two tools to remove waste which will enhance productivity, Value Stream Map (VSM) and Overall Equipment Effectiveness (OEE). The purpose of using VSM is that it easily highlights the bottlenecks in any existing process. For VSM we need to conduct a time and motion study to understand the structure of an organization. Whereas, OEE helps us measure the ef iciency of our system being utilized. After applying these tools, we easily identi ied the parts which needed improvement in the process. It has reduced our cycle time of sub-assemblies by 50% and transportation time by 60%. This overall enhanced the productivity of the system by 20%. The index of OEE increased by 2%. Our work has improved the productivity of the assembly line in an automotive plant. In the future this work can be further improved by our successors for better productivity, ful illing future customer needs.

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...

Assessment of Lean Manufacturing in a Manufacturing Industry

International Journal of Engineering Research and, 2016

Traditionally operated manufacturing industries are facing problems like low productivity, longer production lead time, high rework and rejection, poor line balancing, low flexibility of style changeover etc. These problems were addressed in this study by the implementation of lean tools like 5S, continuous flow, quick change over, total productive maintenance. After implementation of lean tools, results observed were used to assess the leanness of the plant floor. The key benefit of assessment is to identify the current state of production plant. And also to track the overall performance of the plant and it is evident that the leanness level can be improved by focusing on the key areas. This study is conducted in the steering knuckle manufacturing section in a manufacturing company. It includes time studies and current value stream mapping. Lean assessment was carried out using questionnaire which helped in diagnosing the lean status.

Literature Review on Implementation of Lean Manufacturing Techniques

International Journal of Advance Research, Ideas and Innovations in Technology, 2015

In competitive environment lean manufacturing is necessary in every industry. Lean production is a standard manufacturing mode of the 21st century. Lean manufacturing have various synonyms like lean management, lean production, It is very use full techniques for reduce the flow of non value added time. Lean manufacturing is a philosophy to reduce the time between customer order and products are ready for the delivery by eliminating waste. Waste (muda) is a serious problem in to the industry it is creates a non value added services and poor quality of the product. Waste are seven type occurs in industry 1) transport,2) inventory,3)motion,4) waiting,5) over production,6) over processing,7) defect. It is eliminate with the help of lean manufacturing. It is an integrated system that gives production of goods/services with minimum buffering costs. This paper gives the literature survey on various type of industry to apply the lean manufacturing, like apply in to automobile industry, and ...