Abstract
The manufacturing industry has seen dramatic improvements in productivity and quality, while reducing cost and lead times by implementing Lean Production System. Focus of lean manufacturing is on cost reduction by eliminating the wastes. Originating from the Toyota Production System, many of the tools and techniques of Lean Production System have been widely used in discrete manufacturing. This system shifted the focus of the manufacturing engineer from individual machines and their utilization, to the flow of the product through the total process. The main objective of this project is to implement lean production system in the manufacturing of Model‘U’ product in Rane (Madras) Limited, Velachery. This will reduce the inventory, set-up time and material travel distance. Thus it can meet the fluctuating customer requirement and sustain with competitor entries with cost advantage and stock. In the approach of lean production system, data regarding cycle time, takt time and inventory were collected and value stream mapping has been plotted. A new layout is designed which helps in achieving single piece flow of parts and establishing better sequence of operations. Productivity has been considerably improved by implementing lean production system. Kaizen for various improvements in the module had been implemented which helps in further development methods of manufacturing.
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