![]() In order to sustain its core competency of the product, the companies have to look for ways to cut down its cost of production and lead time reduction in order to compete with the other competitors. ![]() to increase the productivity by reducing the cost of production and reducing the lead time and thereby sustain the competitive advantage in the competitive global market. They were undergone application of various modern production management tools like downsizing, restructuring etc. INTRODUCTION In the wake of Globalisation, liberalisation and privatization, the major organisations in different industrial sectors are trying hard to cut down the cost of production in order to survive in the highly competitive market. Keywords: Value stream mapping, line balancing, value added time I. This work is done for Kerala electrical and allied limited (KEL), Kundara unit, which producing Brushless Alternator. Reducing non value added time, increases percentage of value added time and reduction of in-process inventory. By incorporating improvements a future state map is constructed. Line balancing is done to minimize the idle time and improve cycle efficiency by reducing the Number. This tool allows companies to map the flow of products from raw material, through all manufacturing steps, till the finished product. Value Stream Mapping is a powerful tool used to map out both the material and information flow for any manufacturing or administrative process. This paper explores the possibilities of value stream mapping in batch production using line balancing to reduce the non value added time in production process and leading to improvement of the process. Also, 160.3% improvement was done in the total production capacity of the company. It was possible to reduce the total production lead time from 16.39 days to 6.67 days. After the implementation of these improvements, a Future State Value Stream Map was plotted. Various lean manufacturing tools were then applied to these processes to either eliminate them or reduce their impact on the total production time. ![]() The processes performed in the current state which were not adding any value to the finished product were then selected as opportunities for improvement. The current state of the assembly line is plotted using Value Stream Mapping, a tool of Lean Manufacturing. This study applies lean manufacturing tools and techniques to an automotive parts industry located in the Gujarat state of India. Lean Manufacturing is a manufacturing philosophy that is now being adopted by many of the big industrial giants across the world to improve the current process. ![]() The term “Lean “was well received by the world and is known worldwide till this day.Industries of this generation are spending a considerable amount of money in Research and Development sector to invent and discover new technologies that would help them increase their profits. Inside the book he used the term “Lean Production“ to describe the Toyota Production System (TPS). Womack conducted a study of the the Toyota Production System (TPS) and published the book “The Machine That Changed the World” and later “Lean Thinking”. The key contributors to the development of the Toyota Production System (TPS) are Taiichi Ohno, Shigeo Shingo, Eiji Toyoda, Sakichi Toyoda, and Kiichiro Toyoda. These fundamental elements are embedded within the functional system at Toyota and Job Instruction is taught and used within Toyota.īeyond TWI, Toyota continued to fine-tuned the concept of Kaizen), using the science of Industrial Engineering as its leverage and later developed its own management system known as The Toyota Production System (TPS). TWI had a direct impact on the development and use of Kaizen and Standard Work at Toyota. One particular company that has embrace TWI & benefited from it was Toyota Motor Corporation. The introduction of TWI formed the basis of the kaizen culture in Japanese industry. (Note: the creation only refers to the usage of ”Kaizen” as a a continuous improvement methodology, Kaizen(改善) existed as two regular Japanese words of the Japanese language even before the introduction of TWI ). A training film produced to introduce the TWI program title: “Improvement in 4 Steps” (Kaizen eno Yon Dankai), and “Kaizen” as a continuous improvement methodology was introduced to Japan. The Training Within Industry (TWI) service was created by the USA government during World War 2 to provide consulting services to war-related industries to cope with the shortage of trained and skilled personnel of these industries.Īfter World War 2, to help restore Japan, TWI was brought in to Japan to help with the rebuilding of Japanese industry. The concept, tools & techniques of Kaizen originates from a program known as Training Within Industry (TWI). Relationship Between Kaizen, Toyota Production System (TPS) & Lean
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