Journal for Research| Volume 02 | Issue 06 | August 2016 ISSN: 2395-7549
Implementation of Lean Manufacturing Tools for Improving Productivity: A Case Study Brijbhushan PG Student Department of Mechanical Engineering Green Hills Engineering College
Onkar Singh Bhatia Associate Professor Department of Mechanical Engineering Green Hills Engineering College
Vikas Ucharia Assistant Professor Department of Mechanical Engineering Green Hills Engineering College
Abstract Present research focuses on the quality improvement at Himachal Pradesh based manufacturing unit a precision machining company for two and three wheeler components. The objective of present research focuses on current Quality Management System (QMS) implemented and to identify the current quality problems that the company faces and to study. Present research is divided into two parts Ethnographic and Qualitative research design. Recommendations and solutions to the problem faced will be suggested to the heads and supervisors, to improve the current quality system, as well as increase efficiency and reduce non conformities. This research only focuses on problem faced in the production section of the company. In the ethnographic part study is focused on plunging of workers and qualitative part research is focused on various causes of rejection. Lean manufacturing tools is considered as the pilot project to solve the problem. Various tools were used such as Multiple activity charts, Pareto chart, PDCA cycles, cause and effect diagram and control chart. With the help of lean tools, plunging of workers come to zero, better working environment is provided to workers, rejection has reduced o 12000ppm from 29000ppm and reduced the loss of organization from 4.02% to 2.79%. Retention of worker saves the training cost. Tool life also increased. Keywords: Ethnographic, Lean Tools, Pareto, PDCA, Qualitative Research _______________________________________________________________________________________________________
I. INTRODUCTION Dynamic and technological world requires organization to be competitive and pioneer with its products or services. Companies are forced to rethink their manufacturing and management approaches to lower costs, waste reduction, improve productivity and at the same time increase quality. It is true that the number of tools, techniques and technologies are available to improve operational performance is growing fast and 5s is also among the pilot tools of industrial engineering to remain competitive in business. 5s requires less effort, capital, and time to make quality products with less number of defects. It is a lean system to manage and manufacture products. Fields et al. recommended that 5S training be imparted to the management, supervisors, and workers and a change management team be formed which can help to bring the necessary change. The 5S system is a lean system used for organizing and managing manufacturing operations so that they require less human effort, space, capital, and time to make products with fewer defects. All these benefits result in greater productivity, better quality, less cost, workplace safety, and high morale. 5Ss lays the foundation for the company’s overall lean production system, and lack of a robust 5S system will make other lean tools ineffective. Implementing 5Ss alone may not bring the desired results, unless it is followed by educating the target work group on the corporate objective and soliciting its support and participation. Worker teams who participate in a Lean Manufacturing project are trained in the use of statistical and problem solving tools as well as project management techniques to define, measure, analyze, and make improvement in the operation of organization by eliminating defects and variability in its processes. The main concept of lean manufacturing is that defects in a given process can be measured and quantified. Table – 1 Percentage Rejection
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