An Analysis upon Various Improvements and Benefits of Lean Manufacturing: A Case Study of Indian Manufacturing Industries | Original Article

ABSTRACT:

The design of a lean production system is also proposed in this thesis. The lean production system includes a newly designed layout for the manufacturing cell as well as the “operating system" for the cell. The layout is based on the principles of cellular manufacturing in order to promote flow and improve quality. The operating system includes such things as production batch sizes, product routings, and strategic inventory locations. Based on the future state value stream map and supported by a discrete-event simulation, the new operating system is designed to align the lean strategy with the technical capabilities of the manufacturing line. The lean manufacturing system has helped many companies to improve operational performance, mainly in the automotive and electronic supply chains. Although lean manufacturing revealed to be effective for repetitive systems, some small and medium suppliers, faced with high mix and low volume production, have had difficulty to implement the lean manufacturing. The main objective of this study is to analyze lean manufacturing applicability to MTO companies. The results achieved from the case study conducted reveal that lean manufacturing principles, combined with a proper pull mechanism, can be appropriate to MTO, promoting better due date performance and cycle time reduction. As today’s manufacturers face increasing pressure to improve costs and compete globally, many are turning to the philosophy of Lean Manufacturing as exemplified by the Om Components Pvt. Ltd. Pune. Lean is most successful when production is characterized by a few high-volume products, but may not be the answer as the production mix increases and volume decreases.