Lean Tools Execution in a Small Scale Manufacturing Industry for Productivity Improvement- A Case Study

Objective: To study and implement the lean tools and to reduce lead time without much affecting the current working systems in a small scale automotive component manufacturing industry. Method/Analysis: An attempt was made in increasing the capacity of a machining cell with appropriate lean techniques. The enhancement of capacity was to be completed with zero capital investment. Findings: A lean approach by using value stream mapping and line balancing was adopted to improve the performance of the manufacturing cell. By collecting the past production data and deciphering the information, gaps were identified for enhancement. Single Minute Exchange of Dies (SMED) was used to regulate the production and Kaizen was also introduced in all work stations. Leveled operator loading for output consistency was suggested. Finally capacity intensification was achieved without any major capital investment. Application/Improvements: Implementation of lean tools reduced the setup time and idle time. The overall lead time got reduced from 6.9 days to 3.6 days and total cycle time got reduced from 170 to 140 minutes and the customer demand was also met on time by the execution of lean tools.