A study on implementation of lean manufacturing in Indian foundry industry by analysing lean waste issues (original) (raw)

Investigation of lean manufacturing factors for waste reduction in manufacturing SMEs

International Journal of Productivity and Quality Management, 2021

The purpose of this paper is to establish a relationship between various factors of lean manufacturing and the causes of waste in order to guide the practitioners and academicians for adequate implementation of lean manufacturing in their organisations for waste management. A survey has been conducted in various manufacturing organisations of India through a questionnaire on a Likert scale of 5. Further, the gathered data has been analysed using Cronbach's alpha value and the relationship between lean manufacturing tools and causes of waste has been established using canonical correlation test. Relationship among various tools of lean manufacturing and causes of waste has been established using canonical correlation test. The outcomes of this study will assist the floor managers of various manufacturing organisations for the adequate implementation of lean manufacturing in their organisations.

Waste Assessment in an Indian Casting Industry: A step towards Lean Manufacturing

International Journal of Innovative Technology and Exploring Engineering, 2020

In today’s era of globalization, it is essential to ensure that Indian manufacturing industries like casting and metal-working industries which work on stringent conditions of varying customer demands and constant adhering to excellent quality standards are able to flourish in the fiercely competitive environment while keeping the production as economical as possible. Hence, the need arises for continuous improvement in the manufacturing phase of the product by assessing, minimizing, and eliminating wastes of any kind. This study adopts and implements a waste assessment model in a casting industry with the purpose of assessment of wastes and hence, proceed towards a leaner manufacturing set-up. Initially, the quantification of direct relationships between the seven types of wastes was done by forming a waste relationship matrix (WRM). Next, a waste assessment questionnaire (WAQ) consisting of 68 questions, was introduced for the allocation of wastes in the industry. The results of W...

Lean Waste & Lean Manufacturing Techniques

2017

Lean manufacturing began as the Toyota Production System in the Japanese auto industry of the 1970s and 1980s. The objective of this paper is to understand the concept of lean manufacturing, lean waste, its philosophy & various tools and techniques of lean manufacturing. This paper focus on causes and various solutions to eliminate lean waste.

Reducing waste in production by lean thinking - A Case study

Lean manufacturing or lean thinking is one of the widely used industrial technique worldwide and in India now widely used to improve the production efficiency of the industry by reducing the waste ('muda' in Japanese ) which is the main problem of reducing the production. In presented case study, by using the Poka-yoke, tool of lean manufacturing which means error proofing eliminate the root cause because of which defects or waste are produce in the system. Errors may be in operating or in operation carried out on the particular part. In the presented case study, seventeen percent improvement is done by eliminating root cause of rejection which improves the quality of the product and customer satisfaction.

Lean Implementation in Indian Foundry Industries: A Quantitative Survey

The implementation of Lean and the deciding parameters are elaborately studied by surveying the Indian Foundry industry workers. The study conducted in the domain of various demographical factors of age, firm size, education background, gender and years of experience shows cluttering of the data indicating the reasons, benefits and barriers of Lean implementation in Indian sub-continent. 28 Foundry Industries in the state of Karnataka are surveyed with a total of 204 workers providing the input for the intricate questionnaire designed for them. The results indicate that the factors like overall equipment effectiveness, plan-do-check-act, total productive maintenance, bottleneck analysis, continuous flow manufacturing, poka yoke, and standardized work are the most effective categories of Lean. The same is also evident from the standard deviation values obtained from chi-square distribution

A Review -“Investigation on Lean Manufacturing”

International Journal of Advance Engineering and Research Development, 2015

Today, numerous companies have a major opportunity to reduce their costs and customer lead time and cycle time through the application of Lean Manufacturing System or Lean Philosophy. Implementation of Lean helps to improve their productivity and efficiency. This paper aim to have a brief study on the literature related to lean philosophy in the manufacturing industries and integrate the different lean tool for getting better productivity in different industries. The outcomes from this review is hope justify the needs of further research in area of Lean Manufacturing, aimed at strengthen its philosophy towards more realistic applications. In addition, the model also shows how lean dimensions in the manufacturing system related to eight types of wastes.

Lean Manufacturing: An Approach for Waste Elimination

International Journal of Engineering Research and, 2015

Lean Manufacturing (LM), a manufacturing system and philosophy, was originally developed by Toyota, Japan and is now widely practiced by many manufacturers throughout the world. Lean manufacturing is a systematic approach to identifying and reducing waste (non value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. LM is important, primarily because of waste reduction and reduction in lead time. The objective of this paper is to identify Lean manufacturing practices in small scale industries. For this purpose some case studies were chosen and critical observations are identified. Some of these annotations are improper utilization of resources, quality tools for improvements and improper plan for location and layout. This paper includes one case study with the initiatives, observations, results and conclusions of the study carried out in a small scale industry.

Waste Reduction Strategy Using Lean Manufacturing Methods

Increasing the productivity of a company must be done continuously so that allows companies to compete and grow. Therefore, planning must be done well include the improvement and control activities that occur within the company so it can eliminate waste which reduces productivity. One method that can be used to eliminate waste is lean manufacturing. Lean is an ongoing effort to eliminate waste and increase the value added of products (goods and/or services) in order to provide value to customers. The goal of lean is to promote continuous customer value by improving the ratio between the value added to the waste (the waste-to-value ratio). Based on the lean perspective, all types of waste contained along the value stream that transforms inputs into outputs, must be removed to increase the value of products and further enhance customer value. Broadly speaking Lean Manufacturing consists of two stages, Current State Gap and Future State Design. Current State Gap phase is the stage of d...

Some Studies on Lean Manufacturing in Indian Manufacturing Industries

2015

Lean Manufacturing is a systematic approach to identifying and eliminating waste through continuous improvement. The manufacturing industry in India must also look to leverage its advantages, its large domestic market, good conditions in terms of raw materials and skilled labour, and the quality focus. "Lean manufacturing" is a leading manufacturing paradigm being applied in many sectors of the economy, where improving product quality, reducing production costs by reducing cost of poor quality, reduce inventory level, decreased material usage and being "first to market" and quick to respond to customer needs are critical to competitiveness and success. Lean principles and methods focus on creating a continual improvement culture that engages employees in reducing the intensity of time, materials, and capital necessary for meeting a customer's needs. Implementation of Lean Manufacturing is very important in current scenario in Indian Manufacturing industries. ...

VALIDATING THE RELATIONSHIP BETWEEN LEAN DIMENSIONS AND WASTES: A PILOT STUDY OF MALAYSIAN INDUSTRIES

Lean production or lean manufacturing has become one of the most well-known paradigms for the elimination of waste in the manufacturing industries. Past research in lean shows that there are some set of techniques, tools and practices which have been applied to certain levels across firms according to the respective understanding of lean production of the persons in charge of lean initiatives. This scenario led to various versions of leanness measurement in the manufacturing industry. This paper describes a pilot test analysis in validating a conceptual framework for measuring leanness in the manufacturing industry. This conceptual framework has been developed based on a new definition of lean in the context of Malaysian industries. The right perception of lean is crucial in order to develop the right measurement of true lean. An in-depth study of literature consisting of books, journals and conference articles contribute to the development of the conceptual framework. There are seven main dimensions in measuring leanness in lean manufacturing practices such as manufacturing process and equipment, manufacturing planning and scheduling, visual information system, supplier relationship, customer relationship, workforce management, and product development & technology. In addition, the framework also shows how lean dimensions in the manufacturing system relate to eight types of wastes. A questionnaire has been developed in this study to collect data from the respondents as part of the framework validation process. Descriptive analysis is used to compute the evaluation of data that have been rated by the respondents by using the five-point Likert scale. Respondents of this study are experts from the domain of lean manufacturing in Malaysia.