Emerging trends in Engineering & Management for Sustainable Development 2016 International conference, Feb 2016

Productivity Improvement In Manufacturing Sector Using Lean Manufacturing Techniques Anil Kumar Chaudhary Department of Mechanical Engineering,Malaviya National Institute of Technology Jaipur,J.L.N. Marg, Jaipur [email protected] Mohan Lal Sharm Department of Mechanical Engineering,Malaviya National Institute of Technology Jaipur,J.L.N. Marg, jaipur [email protected] Makkhan Lal Meena Government polytechnic college, Churu, Rajasthan [email protected]

Abstract:

Higher

productivity

is

essential

for

the

development of any country. Living standard of people in any

country

depends

on

its

productivity

growth.

Productivity growth required better resource consumption and

minimization

techniques

are

of

used

waste. for

Lean

maximizing

manufacturing the

resource

utilization through minimizing the waste. Today business environment are rapidly changing so organizations are facing challenges and complexities. The success of any organization depends on its ability that how consistently organizations are responding to any rapid change and to enhance the product value. So today it is the basic requirement of the organization to implement the lean manufacturing. For successful implementation of lean organizations should focus on all aspects such as cellular manufacturing (CM), value stream mapping (VSM), single minute exchange of die (SMED), flexible manufacturing, and pull system. This paper illustrates how productivity can be improved using lean manufacturing. Index Term: VSM, SMED, flexible manufacturing, pull system.

time reduction, improvement in cycle time, processing time, setup time, inventory, scrap and defects. Lean manufacturing also includes various qualitative benefits such as effectual communication, satisfaction of job, decision making ability of team, standard housekeeping and improved employee drive etc. The term lean manufacturing came from the Massachusetts Institute of Technology when there was a researcher‟s programme based on international motor vehicle programme. The idea of lean manufacturing is popularized by the Womack et al. [1] through their book The Machine that Changed the World. Toyota production system traced the modern concept of lean manufacturing, pioneered by Taiichi Ohno and Shigeo Shingo, the Japanese engineers. Productivity improvement is the aim of every manufacturing firm, the concept of lean manufacturing provides more productive and more effective manufacturing by reducing all forms of waste from production process. The aim of lean manufacturing is to perform the production with zero defects, to meet customer demand, to reduce cost, to reduce inventory, to reduce unnecessary motion and to eliminate all type of waste. 5S, a lean tool ,consist of 5 terms which help lean manufacturing and visual checks, define workplace practices, and are interrelated in terms of letter „S‟. Delays in the production process takes place due to the breakdown during the production .These breakdown can be only reduced by performing maintenance in a scheduled and planned way. Total productive maintenance is a lean tool which reduces breakdown time in production process. so total productive maintenance improve the productivity of the manufacturing firm by reducing the breakdown time. Today Lean manufacturing technique is one of the most important tool to remain the organization in competition in global market.. The goal of the lean manufacturing is to reduce the non value added activity and to increase the value added activity in production process. Lean manufacturing used a lean tool known as

I. INTRODUCTION Lean manufacturing is one of the most important tools used in manufacturing sector for producing quality product and enhancing the productivity of the firm. After 1945, Japanese companies realized that they did not able to rebuild despoiled facilities with available resources so the concept of lean manufacturing is originated. Lean manufacturing gives manufacturer a competitive environment by enhancing productivity and quality while reducing cost. Lean manufacturing include various quantitative benefits such as production lead ETEMSD2016078 Copyright © 2016 ETEMSD

Emerging trends in Engineering & Management for Sustainable Development 2016 International conference, Feb 2016

value stream mapping, which identify and eliminate all types of wastes from the production process. Value stream mapping is also used to identify the value added and non value added activity. So by reducing the non value added activity and cycle time, value stream mapping improves the productivity of the firm. Mass production was the most important production process used, until the 1980s in western hemisphere. [2]. on the other hand, after the experience of lean manufacturing basics [1], the western manufacturing companies changed their production process as a result significant growth in Productivity, in costs and in delivery time, in quality [4]; [5]; [6]. Almost all the manufacturing firm and service industries applied lean tools in their organizations, and getting benefited. [7]. So lean manufacturing becomes the central concern for those organizations, willing to manage their organizations in better ways.

The features of both craft production and mass production is combined by the Lean manufacturing system. [1]. Lean manufacturing enhance the productivity of each sort of firm by reducing all the wastes from the production process. Lean manufacturing is used to combine different types of equipments and strategies in product development process, operation management and supply chain management, in a logical manner. [3]. Lean means to use minimum or less of each resources either in conversion of raw material into finished product or in providing a service [14]. The term lean manufacturing denotes a system that needs less of all inputs for obtaining the same output of more varieties [15]. Lean manufacturing provides optimum utilization of skills of workers and it gives multiple tasks to the workers by combining the direct work as well as indirect work. So, lean production system produces a higher quality and larger verity product at lesser production cost ,less human effort, less space, less investment, less waste and less development time as compared to traditional production process [16]. Lean manufacturing is a system designed to establish on the hypothesis that sustained product benefit is unlikely, and consequently rather than avert competition, face it head-on [17]. Lean manufacturing is a production philosophy which is optimizes all resources used in different processes of enterprise. Lean manufacturing includes identification and elimination of non-value added activities in production, design, dealing with customer wants and in supply chain management. The organizations practices lean manufacturing requires a team of multi skilled employees at each stage of the organization. Lean manufacturing uses flexible automated machine for producing large volume and more Varity products [18]. Lean manufacturing is a production system which is based on the Toyota Production System and other Japanese firm‟s practices that tries to reduce the time between the order placed by the customer and delivery of the final product by continuously reducing various types of wastes [19]. Findings of different researchers of different countries with their research year are shown below in table 1. Authors are using lean manufacturing in various organizations for improving the performance and enhancing the productivity. Role of various authors with their year of research and their field of research are shown in table 1.

II. LITERATURE REVIEW Lean manufacturing implementation requires various types of lean tools in which one tool is value stream mapping which defines value stream as “ every activity either it is value added activity or non value added activity both are requires to convert the raw material into finished goods/product through the mapping of process and information flows essential for every type product and service” [8]. Other lean tool is pull and push System, pull system is based on the customer needs. In pull system product is manufactured if customer placed order, it is a make to order type system. While push system is based on predetermined demand, which is a forecasted demand. Push system works on build to stock type manufacturing system. [9]. Cellular manufacturing is used to group different types of facilities involved in the production process. The main benefits of grouping the facilities are that, it minimizes process time, waiting time, and transportation with smooth process flow. U-line concept and line balancing is used to improve the fluctuation line flow. Kanban is used for controlling the flow of material in a production process. Kanban allows the flow of right quantity material at right time, so it reduces material requirement in a production system [10]. Production stage and withdrawal stage are the Stages of Kanban Implementation. Single piece flow and just-in-time production system is used to reduce the interruption between processes. Single peace flow provides straight forward scheduling and reduces back flow of resources, so it minimizes the operator‟s mistake and machine failure [11]. Single minute exchange of dies (SMED) is used to reduce the setup time by converting internal setup into external setup [12]. Production Levelling is a lean tool used to increases the production efficiency as well as production volume with the reduction in wastes, unevenness and over load of man or machine [13]. Lean manufacturing is based on systematic set of rules which provides continuous improvements by eliminating or reducing the wastes from each process. ETEMSD2016078 Copyright © 2016 ETEMSD

Emerging trends in Engineering & Management for Sustainable Development 2016 International conference, Feb 2016

Table 1. S no. 1.

Year

Country

Author

Research contributions

2002

Australia

Cooney

2.

2002

UK

Yusuf and Adeleye

3.

2002

USA

McDonald et al

4.

2002

Norway

Kalsaas

5.

2003

USA

Motwani

6.

2003

Taiwan

Wu

7.

2004

UK

Bruce et al

8.

2004

UK

Hins et al

9.

2005

USA

Doolen and Hacker

10.

2005

USA

Furterer and Elshennawy

11.

2006

UK

Bhasin and Burcher

12.

2006

UK

Conti et al

13..

2006

India

Kumar et al

14.

2007

USA

Krishnamurthy and Yauch

15.

2007

USA

Abdulmalek and Rajgopal

16.

2008

USA

Naslund

17.

2008

India

Seth et al

18.

2009

USA

Cooper

19.

2009

Italy

Braglia

Application of lean manufacturing in batch production in Australian automotive industry. Threats to lean and the driver of agile manufacturing through a survey of UK based manufacturing firm. Simulation is used as a value stream mapping tool in a manufacturing firm. Analyze the subcontracting case of value stream mapping in a Japanese automotive industry and improve the throughput time. Examine the critical factors involved in lean implementation in an automotive industry. Examine the connection between the lean manufacturing and different aspect of logistic system with a comparison between lean suppliers and non lean suppliers. Applicability of lean, leagile and agile approaches in supply chain management in textile and apparel industry to reduce the lead time and quick response. Literature review of lean manufacturing, expansion beyond the auto industry over time. Lean practices evaluation in electronic manufacturers where deployment depends on operational, economics or organizational factor. Application of six sigma, lean manufacturing and total quality management in local government for improving the quality and reduce the time of providing the service The conceptual discussion of the failure and success of lean implementation. Evaluates the impact of Lean manufacturing on physical and mental job stress through a multi-firm empirical study by applying Karasek job stress model Combining six sigma methodologies with lean tools to obtain dramatic results in cost, quality and time by focussing on process performance. A theoretical model of leagile manufacturing is analyzed With a case study in a single organization with multiple business units. Value stream mapping is analyzed via Simulation in a process sector (steel firm) to see the remarkable benefits in reduction of manufacturing leads time and lower the work in process inventory. Comparison of the aim, approaches, tools, history and crucial success factors of Just in time, six sigma with lean tool and total quality management through literature review. Different types of wastes in the supply chain of the Indian edible cottonseed oil industry is analyzed using value stream mapping approach to enhance productivity and capacity utilization. Development of the lean production curriculum deployment models in university in conjunction with competency planted earning activities. Described optional approach based on fuzzy algebra and statistics.

ETEMSD2016078 Copyright © 2016 ETEMSD

Emerging trends in Engineering & Management for Sustainable Development 2016 International conference, Feb 2016 S no.

Year

Country

Author

Research contribution

20.

2010

Italy

Villa

21.

2010

Malaysia

Rashid et al

22.

2011

UK

Grove et al

23.

2011

USA

Hodge et al

24.

2012

India

Gupta et al

25. 26.

2012 2012

Sweden UK

Assarlind et al Atkinson et al

27.

2012

Greece

Psychogios et al

28.

2012

Greece

Pdychogios et al

29.

2013

Taiwan

Ming-Te et al

30.

2013

Germany

Metternich et al

31.

2013

UK

McLaughlin et al

32. . 33.

2014

India

Bhamu et al

2014

China

Widener et al

34.

2014

USA

Fullerton et al

35.

2014

India

Sundar et al

36.

2015

Turkey

Arslankayaet al

37.

2015

Turkey

38

2015

Thailand

Buyukozkan et al Choomlucksana et al

39

2015

Indonesia

Hartini et al

40

2015

Sweden

Andersson,

Expose some basic principle of lean manufacturing, six sigma and automation, and their fitness in firms for enhancing performance by reducing the wastes. Evaluation of lean manufacturing in Malaysian Food industry using Value stream mapping to reduce the number of operator and lead time. Application of value stream mapping to map the essential task for the health visiting services which also includes stakeholders to remove waste processes. Analysis of lean principle in a textile company and finds value stream mapping as an important tool from the lean implementation model. Lean Six-Sigma methodology applied in an Indian tyre manufacturing industry which reduces the defective tyres percentage from total monthly production. Discussed the different views of lean six sigma application. Explain the lean philosophy approach in an ongoing nurseled liaison service for elder adults resulted in rising access for elderly medically ill inpatients to mental health service. Examine the effect of critical factors which affects the application of lean six sigma in an aircraft industry and suggested a combine framework for the same industry. For lean six sigma a multi factor application technique is established and used in the telecommunications company along with exploring the critical success factors. Establish lean service performance based model and worker characteristics for improving service and production performance and human resources. Economic and efficiency evaluation of cellular manufacturing to enable lean machining. Cellular manufacturing applications in maintenance and overhaul operations. Literature review and research issues based on the lean manufacturing. Find the complementary and unique effect of lean application and production technology on the performance of manufacturing operation. Measure the performance of the firm using lean tools. The incremental addition of lean manufacturing accounting practices. A Review on Lean Manufacturing Implementation tools and techniques. Lean manufacturing and maintenance management practices in a firm which produces dairy products. Evaluation of lean manufacturing effect on business performance using Bayesian Belief Networks. Successfully applied lean manufacturing tool for improving the productivity of a sheet metal stamping subassembly area The relationship between lean and sustainable manufacturing on Performance of firm Gives the idea about the complexities in performance measure. Enhances production improvement ability by combining over all equipment effectiveness and productivity.

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Emerging trends in Engineering & Management for Sustainable Development 2016 International conference, Feb 2016

[4] Worley, J.M. and Doolen, T.L. (2006), “The role of communication and management support in lean manufacturing implementation”, Management Decision, Vol. 44 No. 2, pp. 228-245. [5] Anand, G. and Kodali, R., “Selection of lean manufacturing systems using the analytic network process: a case study”, Journal of Manufacturing Technology Management, Vol. 20 No. 2, pp. 258-289, 2009(a). [6] Anand, G. and Kodali, R. Application of value stream mapping and simulation for the design of lean manufacturing systems: a case study”, International Journal of Simulation and Process Modeling, Vol. 15 No. 2, pp. 192-204, 2009(b). 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The implementation of lean manufacturing requires integration of lean tools in a sequential manner. This paper suggested that lean manufacturing provides a globalized competitive business environment to the organizations. Lean manufacturing is extensively adopted by each kind of organizations either in production based or in service based organization. It is adopted by all kinds of production systems like product layout, mass production and batch production, process layout, fixed layout and discrete production to continuous production. Lean manufacturing has its application from service sector to manufacturing sector, high varieties and low volume production to mass production system, labour demanding organizations to technology demanding organizations, assembly industry to construction company, communication based industry to medical health based company. The performance of all sectors is improved where lean manufacturing is adopted. Lean manufacturing application provides more stress at administration level as compared to the shop floor people. The critical implementation factors of Lean manufacturing are concurrent application of leanness in supply chain management. One of the cause for the slow implementation of lean manufacturing under variable demand scenario is to link the production pull signal to the capricious demand. Lean manufacturing has become an included system composed of highly incorporated elements and a wide range of management practices. In this paper pre implementation, implementation, post implementation phase are recognized by different issues.. It is expected that this recognition of different issues would assist the managers to effectively grow their implementation plan. So the overall conclusion of this research is that lean manufacturing improved the performance of firm, improves productivity, and reduced inventory, cycle time, wastes, and provides better utilization of all types of resources.

Emerging trends in Engineering & Management for Sustainable Development 2016 International conference, Feb 2016

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