Lean machine manufacturing at Munjal Showa limited

Abstract

Purpose – The global manufacturing industry is becoming more competitive. Munjal Showa, a shock absorber manufacturer in India, is using indigenous development of lean machines by incorporating concepts of lean manufacturing and low-cost automation techniques to increase their competitiveness. This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time. The purpose of this paper is to offer an in depth study of how at Munjal Showa Ltd lean machines are being developed and manufactured. This paper explores how a cumbersome machine was transformed into a lean machine. Design/methodology/approach – This paper explores how a cumbersome machine was transformed into a lean machine. Findings – This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time. Research limitations/implications – The paper discusses the process of converting one cumbersome machine to a lean machine. Practical implications – Creativity before capital. In lean, team brainstorming of ideas and solutions is emphasized instead of spending large sums of money on capital expenditures Social implications – The cockpit model eases pressure of incumbents on the shop floor. Originality/value – The concepts espoused in the paper has increased productivity by 3.45 times and reduced costs.

A Novel Smart Production Management System for the Enhancement of Industrial Sustainability in Industry 4.0

“…In the present scenario, the management team prefers industry 4.0 techniques to enhance productivity by maintaining industrial sustainability within limited constraints. It has been observed that satisfactory results may not be obtained by applying the methodologies developed in the previous research works to other management systems [3,8,22,24,27,50,64,67,69,84]. erefore, in the present research work, such a management system has been developed that can be applied in all types of production conditions.…”

Management and Production Engineering Review

“…Lean as an operational model for MSMEs in developing countries has gained momentum in the past decade [18]. Contemporary literature indicates similar trend with the extension of lean implementation to Indian small and medium enterprises.…”

“…[ [16][17][18][19][20][21] Lean Performance includes articles that deliberate impact of lean on organizational performance [14,[22][23][24][25] Studies discussing lean status of an organization i.e. leanness [26][27][28][29] lean implementation in Indian Small and Medium enterprises.…”

Recent Progression Developments on Process Optimization Approach for Inherent Issues in Production Shop Floor Management for Industry 4.0

“…Singh et al [28] developed an approach to convert the cumbersome machine into a lean machine. The approach helped to reduce the cost of manufacturing and increased productivity by reducing cycle time and downtime.…”