Lean manufacturing

The “Make in India” campaign launched recently by the Indian Prime Minister Mr. Narendra Modi is aimed at making India a manufacturing hub and thereby bringing about economic transformation in the country. One of the major objectives of the vision is to make the manufacturing sector contribute to about 22% of the GDP by 2022, going up from the dismal 12.89% in 2013. Going by the 2013 Deloitte Global Manufacturing Competitiveness Index, China is ranked 1, while India is ranked fourth having fallen from its 2010 rank of 2. The fact that Mangalyaan (India’s Mars Orbiter Mission) used predominantly indigenously manufactured components is a positive sign for the manufacturing sector, but India still has a long way to go to match China’s manufacturing sector contributing 30% to its GDP. One of the best tried-and-tested mechanisms that might be effective in pushing the Indian manufacturing sector forward is the proper implementation of lean manufacturing. Lean manufacturing is a relentless process of delivering what the client needs, when they need it, at a value they are ready to pay while utilizing the minimum measure of assets. The central thought behind lean is minimizing waste, hence creating more value for customers with fewer resources. The concept of lean manufacturing (LM) was originated at Toyota plant, Japan after the Second World War as a…

After reading the article International transference of lean production systems by Reynold Peter James we have Known that the Lean production process is more than three decades old and is generally practiced for reduction of waste management and quality management. Toyota started using lean production process in 1950s to Toyota Production System was established on ideas intended to expand stream, dispose of waste of all types, and it acquired an incredible change organization by getting…

Why Should U.S. Companies Invest in Lean Manufacturing? In today’s global market there is an increased need for companies to be able to compete with one another more proficiently. United States manufacturing companies have learned the hard way that it is difficult to compete with manufacturing firms from other countries. Overseas manufacturing firms have traditionally lacked the capital to compete with their United States counterparts in terms of scale, but have nonetheless been capable of…

Today’s global market demands new manufacturing strategies in order to improve the firm’s efficiency and production. In order to overcome the modern day challenges manufacturing firms are taking in to account the management tools and techniques in different forms and names. The most widely accepted and adopted management tool is the lean manufacturing system. It is considered as the best manufacturing practice across countries and industries because of its global superiority in cost, quality,…

Fig. 1.1 Time line of lean six sigma 1.2 Literature Review: A lot of existing literature review articles are accessible on the standalone ways of lean methodology and Six Sigma methodology, however accessibility in the coordinated structure is in rare supply. Still a few endeavors have been made by the researchers in the past to arrange and recreate the current situation of LSS. Assarlind et al.[8]studied about the literature analysis of multi faceted view on LSS application. . They also…

The manufacturing firm situated in Japan is a batch producer of products with a world class quality where their operations were fundamentally different from the final stage assembly line. They had reached a point where they had no additional capacity to meet the rising demand. To overcome this inefficiency and to satisfy the growing demand, Dr. Youngman and his team implemented the Theory of Constraints approach into the organization. They used a production simulator among all management units…

(7a): What challenge does Toyota face? The market for automobiles is mature and the intensity of rivalry is only going to increase as the industry continues to age. Therefore to be successful in the auto industry, a company must focus on a variety of changing factors or challenges that continue to include demographic, geographic, and technological factors. Another challenge could be the furtherexpansion of its lean low cost manufacturing process. Looking at demographic factors, age is…

Be it a product or service, the Six Sigma methodology is widely uses across manufacturing and transactional projects alike (I Six Sigma, 2016). Effective use of Six Sigma concepts are taught by trained experts to the whole of the team (University of Pennsylvania, 2005). There are tow primary tools of Six Sigma, The Six Sigma DMAIC process (D-define, M-measure, A-analyze, I-improve, C-control) and, The Six Sigma DMADV process (D-define, M-measure, A-analyze, D-design, V-verify)(I Six Sigma,…

that Tugger route system is like a bus system where every Tugger is scheduled on time and if you miss the bus you have to wait for the next one. This was one of the lean improvements achieved. In the past, this department was based on taxi system where operators call the Tugger drivers when they need parts. When parts were delivered, it was worth three hours of work time where it needed racks, floor space and double handling for operators from rack area to work station area. They also returned…

The reason case study spans a long time period is that Ariens undergoes a large amount of transformation in many aspects, including the alternation of management which involves the time-consuming establishment of lean methods, upgrading old leadership with newer ones, and relevant changes in the area of strategy and finance. In this specific case, “transformation” means reconstructing management or enterprise changes, establishing new communication channels, and combining both rigidity and…