LEAN IMPLEMENTATION IN MANUFACTURING INDUSTRY: A CASE STUDY

Abstract

In the present business environment, overproduction refers to excess of production over demand of products being offered to the market. This leads to excessive inventory in terms of finished and semi finished goods. Excess production is only relative to a given demand, and insufficient demand is only relative to a given production and thus consider overproduction and under consumption equivalent. Overproduction is the root cause of imbalances, in production sections thereby; the men & machines are either unutilized or being used for over production. The principles of lean manufacturing are very loud in the subject matter and overproduction is the worst form of waste. In this present case, XYZ Company manufacturing automotive products of the same type but in wide variety was chosen for this comprehensive study. This company has problems in-hand regarding movement of material on shop floor, accumulation of material on shop floor, and waiting time in assembly line etc. The probable solution for above mentioned problems is to apply optimization approaches on production system.