Implementation of lean manufacturing and lean audit system in an auto parts manufacturing industry – an industrial case study

Abstract

Lean manufacturing is one of the innovative manufacturing concepts being applied in many industries to avoid the wastages of resources and improving the quality of products and help the company to become more effective and productive. It also focuses on continuous improvements with the total involvement of all employees with optimum utilization of man power and machine by reducing idle time and reducing lead time with help of lean tools like value stream mapping and kaizen. This paper presents a case study carried out in a foundry division of an auto parts manufacturing industry, where lean tools are implemented for the defect reduction and productivity improvement. In this paper, a conceptualized implementation of total productive maintenance practices of lean tools: Kaizen or continuous improvement and value stream map in an auto parts industry are presented. The result shows improved performance in terms of average core rejections, sand leakage and air lock problem.

Lean Implementation in Small and Medium-Sized Enterprises in Less Developed Countries: Some Empirical Evidences From North Africa

“…Lean production is considered as a systematic method for the elimination of waste within a manufacturing process (Dhiravidamani et al ). Its main philosophy is based on considering any activity that does not create value for the final customer as a waste, which should be eradicated.…”

“…This is including both external problems, like the emergence of integration with international marketplace, the ongoing stimulation of globalized competition, shrinkage of markets, and emergence of new technologies through organizations, and internal problems such as high scrap, high levels of inventory, poor quality in products and labor, long lead times, and the existence of many sources of waste in production processes (Salaheldin ; Shafik ). Conversely, lean production concept is considered as one of the more recent productivity improvement programs that could address many of the problems mentioned above (Achanga et al ; Bhamu and Sangwan ; Dhiravidamani et al ; Sukwadi, Wee, and Yang ). Since its appearance in 1990, this new improvement program has shown a great ability to provide manufacturers worldwide a new competitive edge (Anand and Kodali ).…”

Improvement of steel melting operations at a Caribbean company: a lean manufacturing approach

“…• VSM tool has been used in several instances to map the current state of the system and then quality tools applied to identify sources of waste as well as lean strategies were successfully deployed to eliminate or reduce the wastes (Chowdary and George, 2012;Chowdary et al, 2016;Bevilacqua et al, 2017;Dhiravidamani et al, 2018;Chowdary et al, 2018).…”

“…Lean manufacturing (LM) is one such initiative where companies focus on elimination of process wastes to reduce overall cost of production (Watson, 2006;Bhasin and Burcher, 2006;Ruffa, 2008;Wan and Chen, 2008;García-Alcaraz et al, 2014;Chowdary et al, 2016;Bevilacqua et al, 2017;Chowdary et al, 2018). The application of LM tools and techniques have been spanned several sectors such as automotive, textiles, pharmaceutical and food manufacturing by showing variety of benefits to the organisations (Upadhye et al, 2010;Chowdary and George, 2012;Ghosh, 2013;Kumar et al, 2014;Yusup et al, 2016;Srinivasan et al, 2016;Setianto and Haddud, 2016;Sajan et al, 2017;Tortorella and Fettermann, 2018;Dhiravidamani et al, 2018).…”

Propuesta de mejora de productividad basado en un Sistema Básico de Gestión por Procesos en las Mypes productoras de granada en el distrito de Santiago en Ica

“…Esbelta busca reducir las actividades sin valor agregado (como los desperdicios) y mejorar el rendimiento de las operaciones. Dhiravidamani et al (2018) señalan que es un modelo sistemático dentro de un proceso de fabricación con un enfoque multidimensional, que abarca prácticas de gestión como como Just in Time, sistemas de calidad y entre otros.…”