A Novel Technology in Lean Manufacturing

Abstract

In today’s emerging world, as the demands and expectations of the people grow higher and higher every day, so is the competition. Thus to face the demand and to be competitive & survive in the market, industries have to produce superior quality components without producing waste. This leads every manufacturer to optimize and standardize the processes of every component being produced. One such concept employed is “Lean Manufacturing”. In this paper a novel tool in lean manufacturing is applied. The processes are continuously monitored and collected necessary data to generate VSM and declare the CSM based on the available data. Then the takt time graph and the balanced time – Cycle time – Downtime graph were plotted with the help of which, the scopes for improvements are identified and then the targets are obtained. The FSM is also drawn and a time plan for projects is prepared and monitored continuously. Based on the type of process and the project, different tools are adopted to reduce the cycle time, downtime, waste and thereby increase the productivity. By implementing newer tools, the future demand of the process was successfully proved to be met by the existing line itself and the need of an additional line was defeated, thereby making monetary savings. By implementing this system, the productivity can be constantly increased.