Lean capacity planning for tool room: An iterative system improvement approach

Abstract

Capacity planning helps to synchronize demands and production volumes, and assists in early preparedness for dealing with future production imbalances. A tool room of armored manufacturing organization was selected for this work study. Initially, a master production schedule and rough cut capacity plans are prepared based on the delivery commitments of the organization. Time and motion study of the tool room for 28 weeks was performed to determine its current production capacity. It was observed that imbalance between demands and production exists. An iterative system improvement strategy was proposed for exploring the potential of tool room. Lean concepts and methodologies were the essence of the proposed system improvement strategy. It was observed that WIP had been reduced by 18 %, production volumes had improved by 24 % and tardiness reduced by 28 %. This strengthened our belief that lean philosophy is equally applicable within the capacity planning domain. The capacity planning approach presented in this work study could also be generalized for other domains. This approach believes in improving the potential through elimination of wastes, process improvement, defect prevention and total preventative maintenance. This approach improves the system optimally by utilizing existing resources available on the shop floor. This research will be further expanded towards the major production units of this organization. We are currently working on capacity planning for rebuilding the activities of T-80 UD battlefield tanks.