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Lean implementation and its benefits to production industry

Bhim Singh (Department of Mechanical Engineering, Galgotia's College of Engineering and Technology, Greater Noida, India)
S.K. Garg (Department of Mechanical and Industrial Engineering, Delhi Technological University, Delhi, India)
S.K. Sharma (Department of Mechanical Engineering, National Institute of Technology, Kurukshetra, India)
Chandandeep Grewal (Department of Mechanical and Manufacturing Engineering, Schulich School of Engineering, University of Calgary, Calgary, Canada)

International Journal of Lean Six Sigma

ISSN: 2040-4166

Article publication date: 28 May 2010

8718

Abstract

Purpose

The purpose of this paper is to discuss the lean implementation process and its quantified benefits for the production industry with the help of value stream mapping (VSM). Both current and future state maps of the organization's shop floor scenarios are discussed using VSM techniques in order to highlight improvement areas and to bridge the gap between the existing state and the proposed state of shop floor of the selected industry.

Design/methodology/approach

VSM process symbols are used to discuss lean implementation process in the production industry. The existing status of the selected manufacturing industry is prepared with the help of VSM symbols and improvement areas are identified. Some modifications in current state map are suggested and with these modifications a future state map is prepared.

Findings

After comparison of the current and future state of shop floor of the selected industry it is found that reduction in lead time was 83.14 percent, reduction in processing time was 12.62 percent, reduction in work‐in‐process inventory was 89.47 percent, and reduction in manpower requirement was 30 percent. The rise in productivity per operator was 42.86 percent.

Research limitations/implications

The findings are limited due to the focused nature of the case study and further cost‐benefit analysis can be carried out.

Practical implications

This paper will be very useful for the researchers and practitioners for understanding lean implementations and its derived benefits.

Originality/value

The paper is a real case study showing lean implementation and its benefits for the production industry.

Keywords

Citation

Singh, B., Garg, S.K., Sharma, S.K. and Grewal, C. (2010), "Lean implementation and its benefits to production industry", International Journal of Lean Six Sigma, Vol. 1 No. 2, pp. 157-168. https://doi.org/10.1108/20401461011049520

Publisher

:

Emerald Group Publishing Limited

Copyright © 2010, Emerald Group Publishing Limited

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