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Application of lean manufacturing in automotive manufacturing unit

Jagmeet Singh (Department of Mechanical Engineering, Guru Nanak Dev Engineering College, Ludhiana, India)
Harwinder Singh (Department of Mechanical Engineering, Guru Nanak Dev Engineering College, Ludhiana, India)

International Journal of Lean Six Sigma

ISSN: 2040-4166

Article publication date: 9 October 2019

Issue publication date: 14 January 2020

Abstract

Purpose

This paper aims to apply lean manufacturing using value stream mapping (VSM) in the manufacturing organization (automotive suspension and fastening components section). To validate the VSM approach, simulation has been done.

Design/methodology/approach

VSM approach has been used to implement lean stages in the U-bolt section. Current state map was prepared and future state map has been implemented. Further, simulation has been done to compare current state and future state maps.

Findings

It has been found that there is 87.59% reduction in cycle time (C/T), 76.47% reduction in work-in-process (WIP) inventory, 95.41% reduction in production lead time, 66.08% increase in value added (VA) ratio, 95.78% reduction in non-value added (NVA) time, 57.14% reduction in the number of operators and 70.67% reduction in change over (C/O) time for the U-bolt section. Simulated and VSM of current and future state has observed error of 5 s.

Research limitations/implications

This study is based on automotive manufacturing industry situated in northern part of India. The outcome of this study is applicable only to the selected product of the manufacturing company.

Originality/value

This paper deals with case study part which reflects the true picture of implementation of Lean manufacturing (LM) tools in the organization.

Keywords

Acknowledgements

The authors would like to thank M/S G.S. Auto International Ludhiana for providing work facility to carry the research work. The authors are also indebted to the Editor-in-Chief and anonymous reviewers for their valuable suggestions.

Citation

Singh, J. and Singh, H. (2020), "Application of lean manufacturing in automotive manufacturing unit", International Journal of Lean Six Sigma, Vol. 11 No. 1, pp. 171-210. https://doi.org/10.1108/IJLSS-06-2018-0060

Publisher

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Emerald Publishing Limited

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