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Study of Lean Manufacturing for Manufacturing of Auto Components

Experiment Findings · April 2018

DOI: 10.13140/RG.2.2.18963.17443

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 Study of Lean Manufacturing for Manufacturing of Auto
Components
1
Shyam Lal Sharma 2Prashant Mudgal 3Amit Kumar Jha 4Ashok Kumar 5Govind Kumar Singh
2,3,4,5
UG Students
1
Assistant professor, Mechanical Engineering Department
Noida Institute of Engineering and Technology, Greater Noida, UP, India

Abstract- Lean manufacturing is the manufacturing

philosophy and the system that was given by the Lean manufacturing often simply “lean”, is a
Toyota, Japan and now the many of the systematic method for the waste minimization with
manufacturers are using these techniques in a manufacturing system without sacrificing
industries. “Lean is simply a systematic technique or
productivity. This philosophy is derived from the
approach to identify and eliminating the waste
Toyota production system (TPM) identified lean in
through the continuous improvement by flowing the
product at the pull of the customer in pursuit of the
1990’s. It’s basically also deals with the wastage
perfections. The main aim is to eliminate the produce due to over production, transportation and
wastages in every area of the production including waiting etc. as in Malaysian automotive
the customer relations and the product design and components manufacturer an interview is to be
suppliers”. Lean tools and approach are very much considered that were used to investigate on how
popular in the automobile component manufacturing the implementation is to be done. Kaizen can be
which is improving the growth initiatives in the roughly translated as the continuous improvement
automobile industry in last two decades. In system and it is suitable to a production line. Also
automobile these lean tools like JIST,5S, Six Sigma,
the implementation approach of lean
FIFO, LIFO, Continuous Improvement, JIS,
manufacturing depends on the model line
Kanban processes also helps in the rapid
development and growth in assembly line and overall structures like small area, bottlenecks and delivery
production and growth specially in automobile area. It basically also helps in maintaining the
sector. Nowadays almost 70% to 80% improvement inventory level and in lean manufacturing the
in most of industrial growth is due to the approach of following principles has to be considered like
lean manufacturing. value, value stream, flow, pull, perfections etc.
Keywords: JIST, 5S, Six Sigma, FIFO, LIFO, The basic purpose of this study to know about the
Continuous Improvement, JIS. practical analysis and improvement process of lean
tool.
I. INTRODUCTION

Lean manufacturing often simply “lean”, is a

systematic method for the waste minimization with
a manufacturing system without sacrificing
productivity. This philosophy is derived from the
Toyota production system (TPM) identified lean in
1990’s. its basically also deals with the wastage
produce due to over production, transportation and
waiting etc.
Lean technique in wheel manufacturing industry
 II. RESEARCH METHODOLOGY percentage

The research methodology used in this is a study 90

of lean manufacturing tools practical analysis and 80
the improvement in the industry carrier wheel pvt
70
ltd. This study allows the researchers to know
60
about the principles, processes and the application
of these tools in a auto component (wheel) 50
percentage
manufacturing industry. The industry uses the 40
following tools like Jit, Jis, 5S and continuous 30
improvement in the production line or assembly 20
line and in the quality inspection department. In 10
this we have seen the practical applicable process 0
of these tools which helps in improvement of the 2013-2014 2014-2015 2015-2016 2016-2017
productivity, efficiency and the overall growth of
the industry by reducing the wastages. It also helps Percentage improvement in the production line process
in maintain the wastage of over-production,
waiting, inventory waste. It also shows how
actually the implementation of the lean ii) 5S-
manufacturing in the industry has undergone and It is one of the lean approach developed by the
shows the improvement of the industry. The Japan so, as to maintain the proper standard and
following lean manufacturing method is as enables the just in time manufacturing. It is the
follows. system which is used to reduce the wastages and
optimum productivity so, as to maintain the order
i) Continuous improvement system- sequential. It is the methodical way to organize
It is one of the Improvement Process that helps us your workplace and your working areas as being
to improve efficiency on the production line i.e. on overall philosophy and the way of working it
Up to 2%. It also helps us to improve the work splits into the parts like (seiri, sieton, seiso,
flow in an organization. This approach is mainly seiketsu, shitsuke).
used in the development of the process. The Sort – it makes the work easier by eliminating the
methods are:- wastages on the rim production line.
Set in order- the operations and the operations is
• Define
arranged in proper order so, as to get the finished
• Measure
product.
• Analyze Shine- workplace should be clean and free from
• Improve dust material so as to improve the quality.
• control Standard- machine, worker standard should be
The process of the continuous improvement is properly maintained to manufacture a product.
done in the automobile industry in rim assembly Sustain-it is the goal oriented process.
line, improvement in the sheet metal sheet and
improvement in the pickling process to remove the Implementation-
corrosion. Implementation of this was started in • Transmit the proper information
2013 in the industry and has overcome the four • Transmit the standards
methods:-
• Built standards on the workplace.
• Apply a personalize approach to
• Warning when abnormalities occur.
workforce management.
• Stop the abnormalities
• Integrate your tool
• Defect prevention (error proof)
• Overcome with the score carding and the
Finally, 5s also helps us to improve the quality and
sound governance.
maintains the proper sequence for the overall
• Communicate your success. growth of the industry.
 This technique was started in the year 2013 in the
wheel manufacturing industry (carrier wheel pvt
ltd.).
This tool is mainly follows in the mass production
when the quantity of the product is not very large
also when there is a variation in the cost. There is
also an visual management, it is usually easy to see
if a fifo lane is full or empty giving a lot of clues
on the status of the system.

Implementation of the lean system 5s

iii) Fifo (first in first out)-

It is the lean technique which means first in first
Fig. shows the first in first out process
out. The part the goes in will be the first that goes
out. This technique helps to maintain the proper
order and systematically sequence. In this there is
also a limit to the no of parts in the Fifo lane. This iv) Just in Sequence-
also refers to ensure that the older stock should be Jis is also one of the lean techniques that are
used first and thus maintains the absolute mainly used to maintain the sequence in
inventory. Nowadays this system is almost used in operations, machining and production parts. Jis
all the industry which helps in maintaining the also helps to improve the quality of the product
proper level and thus, improves the quality of the and sequential level. Jis has a major role in him
product by reducing wastage and leads to increase reducing the wastages and also helps to reduce the
the production rate in this the several system and mismatch in the assembly line. Jis in sequence
several inventory models like the economic order approach is to be maintained with the just in time
quantity, multiple order inventory level is being technology. The product to be manufacture must
used. be pass from stage to stage to stage so that is
The principle and practice of maintaining precise
become helpful for the operation and as well as for
production and conveyance sequence by ensuring the system to be maintained. Finally from the
the first part enter a process or storage location is industry base point the focus of the lean
also the first part to exist. It is generally necessary manufacturing helps in reducing the work in
for the pull system implementation. process inventory. By this the following wastages
The following points are to be considered as the are going to be reduce.
part of the FIFO system:-
• Wastage of over-production
• Materials used are drawn from the cost
• Wastage of waiting
record in logical and in the systematic
• Wastage of unnecessary transportation
manner.
• Wastage of defective inventory
• Movement of the material is continuous, • Wastage of unnecessary motions
orderly manner that represent the • Wastage of defected product
condition that is necessary and consistent Therefore, it is necessary to maintain the proper
with the efficient material control. quality and sequence to set-up the lean
manufacturing techniques.
V Just in Time 6. Cost of implementation
Just in time is also a technology that is actually
means for mass production which means the right 7. Cost of changing the existing structure
material at right time at right place and in right
order. Just in time manufacturing also helps us to 8. More tools/equipments/workbenches
improve the productivity and overall growth of the
industry. By using this technique he wastages are
reduced in the industry and quality of the product V. APPLICATIONS
(rim) gets improved. It means where there is order
of the discs and rims on the production line the 1. Education
material needs to there. This technology has given
the good quality by reducing the cost and proper 2. Health care
quantity of the raw material to be supplied. By
using this technology the standards is properly 3. Agriculture
maintained in systematic manner.
4. Financial services

5. Military and government services

III. ADVANTAGES
6. Software and IT services
1. Improved quality of the product
7. Law
2. Increased efficiency and maintain proper
standards.
VI. CONCLUSION
3. Easier to manage the work area.
The purpose of this study was to investigate how
4. Reduce the space by reducing the the implementation and practical analysis of lean
wastages. manufacturing techniques and their tools work in
the automobile industry. In the project lean
5. Safer work environment manufacturing for manufacturing of the auto
components leads to reduce the wastages an
6. Improve the employee morale inventory level to be maintained which is the
mother of the waste. After reducing the inventory
7. Problem elimination level wastage is automatically reduced. By this
way the optimum performance on the assembly
8. Increased the productivity line and on the inspection and testing line. There is
also a tangible benefits in reducing the cost saving,
space saving and process improvements etc.
therefore. Lean is a continuous improvement
IV. DISADVANTAGES- process if we carry in a right way it may also
results achieve simply fantastic. The major
1. Time factor which reduces the outcome after it has got perfectly implemented in
productivity the automobile industry is that it mainly requires
the team work also and to reduce the lead time
2. The human factor from start of manufacture of the product to the
dispatch time and flexibility of the product is also
3. Lack of proper IT systems get improved. At last, we conclude that the project
of lean manufacturing for manufacturing of the
4. Unbalanced economies auto components gives us the knowledge of to
maintain our product level which helps to the
5. Negative perceptions by the staff overall development.
 VII. FUTURE WORK

Future work of lean manufacturing is further going

on which leads to increase the percentage of the
improvement and the quantity of manufacturing of
the components by reducing their lead time. In
future the further research is also going on to make
this approach stable both in large as well as in
small scale industries. This also leads to give more
output by giving the lesser input that leads to the
growth of the productivity.

VIII. REFERENCES

1. R. j. Schonberg, “Japanese production

management: an evolution – with mixed
success,” journal of operation
management, vol. 25, pp. 403-419, 2007.

2. M. Holweg, “the genealogy of the lean

production,” journal of the operational
management, vol.25, pp.420-437, 2007.

3. T. James, “wholeness as well leanness,”

Iet manufacturing engineer, pp.14-17,
2006.

4. Taylor l. And matichenkor.,(2006), “lean

transportation fact or fiction”. An
executive white paper. Pp-7.

5. J. Seliger, k. awalegaonkar, c. Jampiris, G.

Bellano, so you want to get lean kaizen or
kaika ku, Oliver wyman, 2007.

6. Womack, j.p. and jones, d.t., lean

thinking: banish waste and create wealth
in your organization. NY: free press,
2003.

7. Jerry Kilpatrick (2003), “lean principles”,

Utah manufacturing extension partnership.

8. Ahlstrom, p., 1998 “sequences in the

implementation of the lean production”,
European management journal 16,
pp. 327-334.

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