Ashish Tiwari

Dr.V. K. Sukhwani

Neeraj srivastava

Abstract

In today's scenario competition and demanding customers are increasing day by day and therefore different organizations are continually trying to increase productivity & output of their operations to satisfy customers with the exact product, quality, quantity and price in the shortest possible time. This can be achieved by implementation of lean manufacturing, which refers to as a manufacturing improvement process based on the fundamental goal of Toyota production system (TPS) to minimize or eliminate waste while maximizing production flow. The Purpose of this case study is to apply Lean manufacturing in automotive industry where clutches of different sizes for heavy vehicles are assembled. The aim was to find wastage and eliminate it through transformation of traditional batch production into one piece flow. In this study, one piece flow methodology based on lean concept was applied in the assembly section of company. Highly encouraging results have been obtained by this implementation. Some of the results are, Lead time decreased by 61%, Number of operators required to produce equal number of clutches decreased by 34%, productivity increases from 8.26 to 12.66 nos / man and Work in process inventory (WIP) reduces from 40 to 10 i.e. 75? reduction. Similarly floor area requirement reduced from 112.5 square meters to 60 square meters i.e. 47 ? reductions. The result of study shows that implementation of one piece flow methodology significantly reduces wastage in industry.

Keywords- Lean Manufacturing, One Piece Flow Methodology, Toyota Production System.