Title: Analysis of lean manufacturing in an automobile industry - a case study

Authors: S. Mahendran; A. Senthilkumar; R. Jeyapaul

Addresses: Department of Mechanical Engineering, University College of Engineering, College of Anna University Chennai, Pattukkottai – 614 701, Tamilnadu, India ' Department of Mechanical Engineering, University College of Engineering, College of Anna University Chennai, Panruti, Tamilnadu, India ' Department of Production Engineering, National Institute of Technology, Trichirappalli, Tamilnadu, India

Abstract: The automobile industries are more competitive and customer demand is volatile. The customers are willing to buy the product at low cost with high quality. So common principle is created to reduce the wastage and increase the efficiency of the industry. Lean manufacturing is the best principle to adopt the manufacturing industry. The main aim of this project is reduce the wastage, cost and increase the productivity of the industry. Using lean tools just in time (JIT), kanban, value stream mapping (current and future state) and man machine chart (current and future) for reduce wastage and cost. In current state value stream map, the waste area is identified. Finally, non-value added time is reduced to 28.7%. The value added time is reduced to 27.84%. The percentage value addition is increased from 3.25% to 3.29%, the total inventory is reduced to 25.07% and man machine ratio is improved as 1.52: 1.26.

Keywords: value stream mapping; man machine chart; 5S; just in time; JIT; value addition; value added time; non-value added time; man machine ration; kanban; automobile industry.

DOI: 10.1504/IJENM.2018.093708

International Journal of Enterprise Network Management, 2018 Vol.9 No.2, pp.129 - 142

Accepted: 02 Nov 2017
Published online: 01 Aug 2018 *

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