Overview of Lean Manufacturing and Its Implementation Techniques

International Journal of Trend in Scientific Research and Development (IJTSRD), 2019

In competitive environment lean manufacturing is necessary in every industry. Lean production is a standard manufacturing mode of the 21st century All the manufacturing industries have put a continuous efforts for its survival in these current world. In order to handle the critical situations manufacturers are trying to implement new and innovative techniques in their manufacturing process. Later on lean was formulated and developed as the solution to the fluctuating and competitive business environment. Due to rapid change in business environment the manufacturing organization are forced to face challenges and complexities in the competition. The concept of lean manufacturing was developed for maximize the resource utilization and minimize the wastes. The main focus of the lean manufacturing is to satisfy customer demands for high quality and low cost. The technique not only identifies the reasons for waste but also helps in its removal through marked principles and guidelines. Lean Manufacturing is an efficient and fast growing approach in the world of competition. Lean manufacturing utilizes a wide range of tools and techniques; the choice of tools is based on the requirement. Many parameters contribute success of lean. Organizations which implemented lean manufacturing have higher level of flexibility and competitiveness. However, lean manufacturing provides an environment that is highly conducive to waste minimization. The majority of the study focuses on single aspect of lean element, only very few focuses on more than one aspect of lean elements, but for the successful implementation of lean the organization had to focuses on all the aspects such as Value Stream Mapping (VSM), Cellular Manufacturing (CM), U-line system, Line Balancing, Inventory control, Single Minute Exchange of Dies (SMED), Pull System, Kanban, Production Leveling etc.,

ijetrm journal, 2021

In manufacturing to profitability improvement applying lean concept can really good. Broad fields of lean manufacturing are simple to get to deal with a broad range of matters found by altered production process. It helps to lessen expenses of the producing products. The elementary Non-Value added Activities were apparent and chances needed for enhancement has been supposed. Value Stream Mapping (VSM) has the position of finding waste during manufacturing and business measure which encourage finding and eradicating or stream the worth added steps. Initiative of lean manufacturing aims on reduction of cost and turnover increases by methodically eradicating non-value-added actions on continuous basis. In current cut-throat setting, lean can be considered as "the solution" to producing firms across the globe for sustained survival.

2020

Abstract: Lean manufacturing is a proper technique to identifying and eliminating waste through continuous improvement. In lean manufacturing do more with less: time (production time, waiting time etc), inventory, men, and money. At present time, Lean Manufacturing has become a worldwide technique. It is very successful in drawing the attention of companies of all sizes. Many organizations are following Lean technologies and experiencing drastically improvements in quality, production, customer service, and profitability. Process improvement is an iterative method of seeking the elimination or reduction of non-value adding work imbedded in a process. Non-value-adding work is described as elements of work that a customer is unwilling to pay for. The Lean manufacturing technique is meant convert non-value added activity into value added activity. Lean manufacturing has its effect on the manufacturer and the customers alike. A lean organization understands customer value and focuses it...

The purpose of this study is to examine how lean techniques are adopted by manufacturing firms in India and their impact on performance. This study gives the opportunity for the application of lean manufacturing techniques in a mix and low volume traditional manufacturing industries. VSM and associated tools are used to explore the opportunities to streamline the flow of products on the floor with a focus on reducing inventory and improving quality. This study has been carried out within the field of lean production. It has been aim to investigate and analyze how a company could implement the philosophy. Lean concept or lean manufacturing is a systematic methodology that identifies and eliminates all types of waste or non value added activities there are components that are considered “waste”. Lean concepts are purely about creating more value for customers by eliminating activities that are considered waste. Any activity or process that consumes resources, add cost or time without creating value becomes the target for elimination.

2015

— In the present global and competitive environment all organizations needs to perform efficiently with higher productivity. For performing efficiently with higher productivity there are so many tools and techniques. Lean is one of them it means using only what is necessary. Lean manufacturing techniques aim to significantly identify waste and eliminate it from the manufacturing processes. The paper is based on a discussion of literature review that shows how the completion of Lean could find importance to the organization processes and contribute for live in competitive environment by fast full benefits i.e. lead time, set-up time, reduction in inventory etc.

INTERNATIONAL JOURNAL OF PROGRESSIVE RESEARCH IN ENGINEERING MANAGEMENT AND SCIENCE, 2024

This study is comprehensive. It looks at how lean manufacturing concepts transform industrial processes. They make them efficient and cut waste. The study uses real-time data to back up its findings. The Toyota Production System is rooted in lean manufacturing. It emphasizes creating value, cutting waste, and improving. The research delves into key lean principles. These include just-in-time production, value stream mapping, 5S, and Kaizen. It also covers their practical use in many industrial settings.

Journal of Intercultural Management, 2013

Lean Manufacturing is a structured program whose objective is to maximize the effectiveness of the company. It is based on the practices and methods of KAIZEN / LEAN applied by the world’s best companies. The experiences from the Author led us to the conclusion that the Lean Manufacturing is based , among others, on the following concepts: - Total Productive Maintenance TPM - Single Minute Exchange Die SMED The Lean Manufacturing focuses on the systematic pursuit and elimination of waste and losses. The losses identified are analyzed, evaluated in adequate manner to the attribute processes. The result of the analysis determines where and how to intervene. In the paper has been presented the bases of Lean Manufacturing. The results of the implementation of Lean Manufacturing in different companies have been described. The main issues of Lean Manufacturing implementation have been characterized.

MATEC Web of Conferences

This research was conducted in manufacturing industry, so this research is based on case study application. This research serves to reduce waste in the industry when making a product. This study categorizes value-added work and which work has no added value. And it is measurable and has value, so it can be evaluated in the future. Later this will be poured or depicted on a map called Value stream mapping. This is a tool from Lean Manufacturing. Lean manufacturing is useful for analysing and reducing non value-added activities, value stream mapping analysis tools, 5L1H process mapping activities, and 5 why tools. From the results of this study obtained the efficiency of the process cycle and total estimation of the improvement of the lead time. This calculation can be an evaluation material for the company.

2018

Many manufacturing cost reduction initiatives have been introduced over past three decades including lean manufacturing. Waste reduction and efficiency improvement are the main objectives of this initiative. It is developed from a set of tools and techniques and can fit nicely in cost focus or cost leadership competitive advantage strategies. But, keeping competitive advantage under the market circumstances are getting harder with growth of production quantity and product diversity. Therefore, paper's focus is lean manufacturing implementation trends and issues within the various manufacturing sector. Successes and failures of implementation of lean manufacturing in some industries are discussed. It was found that lean principles are good source of competitive advantage, it is applicable for many industries and its expansion and discussion are significantly progressing. The biggest threat in implementing lean is lack of understanding the concept but those who engage consultants ...

International Journal of Advance Engineering and Research Development

Survival of any industry in this era of globalization & a cut-throat competition becomes extremely difficult. In order to survive, it is necessary to adapt to this ever changing environment. Globalization has made this competition fierce & has also helped in developing techniques & methods that are exceedingly helpful for any industry to flourish even in today's times. Lean is one such tool that can be applied anywhere & everywhere in industry. From shop-floor to the top management, lean has proved its mettle. Application of lean reduces the wastes that are produced & also helps in streamlining the production system. It focuses on continuous improvement & at the same time reducing the wastage. Widely used techniques like Kaizen, 5S, Six Sigma, Value Stream Mapping (VSM) are a part of lean. Implementation of lean leads to all around development of any industry. This paper discusses comprehensive literature on implementation of lean manufacturing. The case studies considered in this paper includes work of international researchers.