Abstract:
Shifting customer demands, increasing variation in products and demand for perfect
quality at competitive price with shortest lead time are the common difficulties faced
by the manufacturers. Meeting these demands while dealing with complex
distribution systems and multi-tiered chains of suppliers is better understood in light
of system dynamics and finding ways to minimize their cyclical nature. In the
competitive market place, most of the manufacturers tend to stay in business by
optimizing the production cost through minimizing lead time and wastage of
materials along with increasing employees effective skills rather than increasing
prices. In this circumstance lean manufacturing tools and techniques are becoming
the most intelligent parts.
The paper is on the study of lean tools and techniques and present situation of the
industry. The current state value stream mapping identifies the waste happening in
frequent manner. This map shows what will be the future state map what is the
possible scope of improvement. The future state map shows the possible waste
reduction way that contributes to the production lead time. The analysis of 5S and
change over time improve the space utilization and production loss time. There is a
suggestive framework on how to implement lean techniques to get the maximum
benefit from the business depending on the study feedback. To facilitate the
conversion process, the studies point to three critical needs: increased receptivity to
innovative process change, enhanced predictability to the likely regulatory
constraints such equipment will operate under and timely responses to construction
and modification actions.
Lean manufacturing as a continuous improvement program shows the way to
improve the process by eliminating waste, standardizing work, and creating flexible
manufacturing. Typical tools used to achieve this improvement include: line
smoothing, the 5 Ss, cycle time reduction, and work area reconfiguration.
Implementing the lean methodologies is a long journey most likely a never ending
journey that must be carefully planned and frequently revised if one is willing to
succeed.
