Study on implementation of lean manufacturing tools and techniques in the RMG industry

Abstract

Shifting customer demands, increasing variation in products and demand for perfect quality at competitive price with shortest lead time are the common difficulties faced by the manufacturers. Meeting these demands while dealing with complex distribution systems and multi-tiered chains of suppliers is better understood in light of system dynamics and finding ways to minimize their cyclical nature. In the competitive market place, most of the manufacturers tend to stay in business by optimizing the production cost through minimizing lead time and wastage of materials along with increasing employees effective skills rather than increasing prices. In this circumstance lean manufacturing tools and techniques are becoming the most intelligent parts. The paper is on the study of lean tools and techniques and present situation of the industry. The current state value stream mapping identifies the waste happening in frequent manner. This map shows what will be the future state map what is the possible scope of improvement. The future state map shows the possible waste reduction way that contributes to the production lead time. The analysis of 5S and change over time improve the space utilization and production loss time. There is a suggestive framework on how to implement lean techniques to get the maximum benefit from the business depending on the study feedback. To facilitate the conversion process, the studies point to three critical needs: increased receptivity to innovative process change, enhanced predictability to the likely regulatory constraints such equipment will operate under and timely responses to construction and modification actions. Lean manufacturing as a continuous improvement program shows the way to improve the process by eliminating waste, standardizing work, and creating flexible manufacturing. Typical tools used to achieve this improvement include: line smoothing, the 5 Ss, cycle time reduction, and work area reconfiguration. Implementing the lean methodologies is a long journey most likely a never ending journey that must be carefully planned and frequently revised if one is willing to succeed.