Insightful implementation of lean tools to cultivate lean culture in a small scale manufacturing organisation - a case study

Abstract

Small and medium-scale organisations are the backbone of the Indian manufacturing sector. Awareness and proper use of the lean approach can improve their productivity. This paper demonstrates insightful use of some of the lean tools to a small subcontractor organisation; for improvement in its current process with less expenditure. The second objective was to develop an attitude among production people for waste-free practices through innovative ideas. To achieve these objectives, the current state VSM was prepared to identify wastes in the process. Kaizen, pacemaker, PEEP, and two-Bin Kanban system were used to achieve the ideal process. By implementing these tools, the total cycle time for one rotor assembly is reduced by 37.12%, the total lead time is reduced by 7.1%, and inter-departmental material movement per day is reduced by 37.5%. This paper will motivate researchers and practitioners to develop specific but effective solutions with knowledge of lean philosophy.