LEAN MANUFACTURING IN AUTOMOBILE INDUSTRY

Anuj ShahVth sem, Automobile

Parul Institute Of technology

INTRODUCTION Lean manufacturing, is a systematic method for the elimination of

waste (“MUDA") within a manufacturing process. Lean also takes into account waste created through overburden (“MURI") and waste created through unevenness in work loads (“MURA").

TYPES OF WASTE

The two pillars of LEAN MANUFACTURING. Lean implementation is therefore focused on getting the right things to the right place at the right time in the right quantity to achieve perfect work flow, while minimizing waste and being flexible and able to change. These concepts of flexibility and change are principally required to allow production leveling also know as HEIJUNKA.

LEAN MANUFACTURING

JUST IN TIME AUTONOMATION

Lean goals and strategy Improve quality Eliminate waste Reduce time Reduce total costs

THE 5’S OF LEAN MANUFACTURING Much of Lean manufacturing is applying “common sense” to

manufacturing environments. In implementing Lean, 5 S’s are frequently used to assist in the organization of manufacturing. The 5 S’s are from Japanesse and are:

Seiri (sort) Seiton (set-in-order) Seison (cleanliness) Seiketsu (standardize) Shitsuke (discipline)

LEAN MANUFACTURING IN AUTOMOTIVE INDUSTRY

ELIMINATION OF WASTAGE,OVERLOAD AND UNEVENESS Wastage in production( Muda)-

Motion:- Work smart not hard

Wastage of motion is any motion of man

and/or equipment that does not add value

to the product or service.

Wasteful motion can be over come by :-

1)Effective workstation layout, reduces excessive

Walking , bending and reaching while working.

2)Well designed method, locating car parts where they a

Are needed.

3)Small batch size, each batch for special and

specific part or process.

Over Processing Over processing is putting more into the product

then is valued by customers

1)Painting of unseen and unrequired areas.

2)Cleaning and polishing beyond the point required

3)Add-on instrument in cars that are not required

Over –Processing can be over come by:-

1)Standardizing of best techniques

2)Clear specification/quality acceptance standards.

3) Computerised robots for special purpose for even

working and avoid over processing.

The goal is to do only the level of processing to match

that which is necessary and useful.

Over Production Over production is the worst kind of waste because it causes

other wastes and obscures the need of improvement. Over production waste results from producing more than required.Over production can be over come by :-1) Analysing market

2) Demand Of Cars

3) Forecasting of car requirement in certain market in upcoming

month.

4) Stable schedules.

5) Balanced cells and department

Transportation Transportation waste is material movement that is

not directly associated with the value adding process. Process should be close together as possible and

material flow directly from process without any significant

delays in between.

Transportation loss can be over come by :-

1)Using multi purpose transportation layout, which delivers

the parts and product with full capacity. 2) Minimising the distance between different level i.e. Primary,

secondary and Tertiary industry.

3) Working faster then the demand.

Inventory Inventory waste is stock and work in process in excess

of the requirements necessary to produce goods or services

‘Just In Time’. Unnecessary inventory that accumulates before or after

a process is an indication that continuous flow is not being

achieved .

In automobile industry the waste of inventory can be

overcome by:-

1) Proper management of required parts.

2) Achieving effect procedure to assemble the parts.

3) Balancing of work at different stages of assembly.

4) Using of comprised monitored, stock system. Which track the

Requirement of the stock

Automobile manufacturers using Lean Manufacturing Toyota Motor Company, Toyota Production System

Ford Motor Company ,The Ford Production System

Chrysler ,Chrysler Operating System

Porsche ,The Porsche Improvement Process

General Motors ,NUMMI joint venture with Toyota

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