© 2017 IJSRST | Volume 3 | Issue 1 | Print ISSN: 2395-6011 | Online ISSN: 2395-602X

Themed Section: Science and Technology

A Review on Benefits of Implementing Lean Manufacturing

Jinal S Patel*, Dr. Gajanand S. Patange
CHAMOS Matrusanstha Department of Mechanical Engineering, Charotar University of Science & Technology, Changa, Gujarat, India

ABSTRACT

In competitive environment, lean manufacturing is necessary in every industry. Due to rapidly changing business
environment the organizations are face challenges. Any organization whether manufacturing or service oriented, to
survive may depend on its ability and continuously improvement in process. Therefore value adding process is
necessary to achieve this perfection; hence implementing a lean manufacturing system is becoming a part of any
type of organizations to sustain. Moreover, Lean manufacturing are widely used for eliminating various types of
waste and increase profit of organization by making process more efficient. This paper gives the literature survey on
lean tools to apply the lean manufacturing and presents benefits of implementing lean manufacturing.

Keywords: Lean Manufacturing, Lean Tools, Lean Implementation.

I. INTRODUCTION a future state map based on improvement plan. The
availability of the information in the VSM facilitates and
Lean concepts are evolved from Japanese industries validates the decision to implement lean tool and also
especially from Toyota. Lean manufacturing is motivate the organization during the actual
considered to be a waste reduction technique, but in implementation to obtain the desired results. VSM
practice lean manufacturing maximize the value of the clearly indicate the inventory, process time, Lead time,
product through minimization of waste. The waste- waiting time etc and process flow from which we can
elimination concept of Lean manufacturing has a sort out bottleneck cycle time against Takt time.
significant impact on various industries. The goals in
implementing the lean manufacturing are lower 2) Group Technology
production costs; increased output and shorter
production lead times. The paper review focused on the Group Technology is successful implementation of
implementing lean and their benefits, which is achieved flexible manufacturing system which is need grouping
through the tools of lean manufacturing. of parts by using similarity among the design and
manufacturing which make the production plan and
II. LEAN IMPLEMENTATION METHOD manufacturing process flexible. Based on the grouping
of parts through similar process, dissimilar machines are
1) Value Stream Mapping (VSM) grouped together to form a cell concept as suggest by
lean concept. Cell formation is purely based on the
Value Stream Mapping (VSM) is the process of nature of the process which varies from organization to
mapping for the material and information flows required organization.
to know the activities performed by manufacturers,
suppliers and distributors to deliver products to 3) Inventory
customers. Initially a current state map was drawn from
which the source of waste identified and its finds the Inventories are classified into raw material, work-in-
opportunity for implementing various lean techniques. process (WIP), finished goods. Survey from various
VSM facilitates the identification of the value-adding articles indicates that 60% of wastes in manufacturing
activities in a Value Stream and elimination of the non- system are due to inventory. As per literature survey the
value adding activities. A second step in VSM is to draw excess raw material is due to poor projection of product

IJSRST173371 | Received : 15 March 2017 | Accepted : 30 March 2017 | March-April - 2017 [(3)2: 249-252]
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plan, availability of raw material, defective parts, waiting time, inventory and resource problem. In this
waiting for processing leads to more work in process, competitive environment Continuous Improvement is
and unnecessary transportation between working necessary for sustaining in the market, but the success of
stations or plants increases work in process inventory, the Continuous improvement depends on employee,
overproduction of parts beyond the plan leads to finished adaptation, team work, leader engagement, motivation,
goods inventories which wait long time in the warehouse. initiative, and training.
Inventories are reduced by improving the quality levels,
rejection rates, delivery rate, lead time and customer III. LITERATURE REVIEW
satisfaction. Raw material is controlled by ordering
material against the demand. As a result manufacturing Gisela lanzaa(2014) this paper indicate that Quality
lead time increase which is increase the work in process. Value Stream Mapping is capable of systematically
Kanban and Pull system are the lean tools which are visualizing, analyzing and optimizing multistage
control the work in process. manufacturing processes from a quality assurance
viewpoint. The rate of defects and the quality-related
4) Kanban costs were reduced.

Kanban is a lean tool of the Lean manufacturing system Muhammad al-Ashraf(2012) conclude that the VSM
which was created to control inventory levels, the applied to assess the expected impact of a change in the
production and supply of components. During demand production process resulted in savings (lower rejection
uncertainty, the buffer maintenance is necessary for rates) and to a certain extent; a positive view was due to
smoothening production flow by Kanban System in substantial gaps between standardized work and real
order to lower the inventory. Thus Kanban system work. The total reduction of man time was at 16.9%
production for inventory level which are results in less while the machine time was reduced at 14.17%
lead time in product delivery and effective utilization of compared to original processing method.
resources such as man, machine etc.
Darshak A. Desai(2015) conclude that six sigma tool
5) Takt time use for quantitative continuous improvement which
improves bottom line of the organizations by reduction
Takt time defined as frequency of a part or component of costs, waste and non-conformance. Also adding that,
must be produced to meet customers demand. Takt time Quality and productivity can be improved by reduction
depends on monthly production demand, if the demand in rejection, rework, cycle time, idle time and scrap by
increases the Takt time decreases, if the demand application of six sigma.
decreases the Takt time increases which mean the output
interval increases or decreases. Literature suggested that Hiren R. Kardani(2014) conclude that by using value
the importance of measuring Takt time due to the costs stream mapping, we observed that non-value added time
and inefficiency factors in producing ahead of demand, is reduced by 25.6%. Also, the WIP is reduced and
which includes Storage and finished goods. thereby lead time is reduced by 66.7%.This proves the
utility of value stream mapping technique.
6) Kaizen
Santosh kumar et, al(2014) conclude that use lean tool
Kaizen is a philosophy that defined as “Improvement in time measurement for reduce the cycle time in
initiatives that increase successes and reduce failures” assembly line with improve efficiency in that product
Continuous Improvement is the management technique line. Also, as per author, lean manufacturing is a
which effort the cultural change in the workplace. Once business philosophy that continuously improves the
process stability is established, Continuous Improvement process involve in manufacturing.
tools are required to determine the root cause of
inefficiencies in production line. Kaizen tool help us for Mashitah Mohamed Esac(2013) this paper reveal
zero inventories exposes waste such as the idle time, information regarding Kanban system, which is save

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costs by eliminating over production, developing  Reduction of cost
flexible work stations, reducing waste and scrap and
minimizing the waiting times; thus reducing the Summary of Literature Review and Discussion
inventory stock levels and overhead costs of production
(Surendra et al., 1999). Paper Title Jour Tool Benefits
nal applied derived
S. P. Kallurkar(2014) conclude that JIT techniques
1 Quality Value Elsev VSM Reduce
used for reduce non-value added activities, they have Stream ier defect
more time to focus on value added activities, which will Mapping and
improve service to their customers and provide better product
operating environment for the organization. Moreover, cost
JIT also useful for optimizing manufacturing efficiency 2 Production Elsev VSM Reduce
Flow Analysis ier man and
by reducing lead time through waste elimination and through Value machine
kanban system. Stream time
Mapping: A
Nurul Hayati(2012) conclude that lean implementation Lean
Manufacturing
shows that lead time in-process and finished goods
Process Case
inventory and also finished good area will certainly Study
improve lead time reduced by 40%, in-process and 3 A Review of IJAE Six Improve
finished goods inventory minimized by 23-29% finished Six Sigma RD sigma quality
good area optimized by 4%. Implementatio and
n in Indian producti
SMEs – Tools vity
Seyed Mojib Zahraeea(2015) conclude that there are & Techniques
lots of reworks during the production process because of Used and
poor production control. Thus, identifying and Benefits
eliminating waste by using product selection, conceptual Drawn
design, and time frame formulation through talk time 4 Value Stream Elsev VSM Decrease
Mapping: A ier lead
calculation, by using value stream mapping tool, Case Study of time
production lead-time (PLT) has gone from 8.5 days to 6 Automotive
days, and the value added time decrease from 68 Industry
minutes to 37 minutes. 5 Cycle time Elsev VSM Reduce
reduction of ier Tree cycle
truck body diagram time
Ratneshwar singh et,al.(2013) conclude that TPM assembly in
implementation reduce break down time and improve automobile
performance efficiency. Adding that, TPM also depend industry by
on various pillars, like 5s, planned maintenance, quality lean principal.
maintenance, kaizen etc, which are improve the quality
6 Lean Elsev kanban Reduce
of product with over all equipment effectiveness. Manufacturing ier inventor
Case Study y and
Benefits of implementing of lean manufacturing: with Kanban over
System producti
Implementatio on
 Reduction in lead time
n
 Improvement in productivity A Case Study Elsev JIT Reduce
 Quality improvement/ reduce defects 7 of Just-In-Time ier lead
 Reduce cycle time System in time
Service
 Reduction of unnecessary activity
Industry
 Reduction in work in process [WIP] Inventory 8 Development Elsev kanban Reduce
 Waste reduction of Kanban ier lead

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 System at time and Research in Engineering and Technology, 3(1),
Local inventor 310-314.
Manufacturing y [5]. Taj, S., & Berro, L. (2006). Application of
Company in
Malaysia – constrained management and lean manufacturing in
Case Study developing best practices for productivity
9 Production line Elsev VSM Decrease improvement in an auto-assembly
analysis via ier 5s lead plant. International Journal of Productivity and
value stream time. Performance Management, 55(3/4), 332-345.
mapping: a Reduced
lean value [6]. Rahman, N. A. A., Sharif, S. M., & Esa, M. M.
manufacturing added. (2013). Lean manufacturing case study with
process of Kanban system implementation. Procedia
color industry Economics and Finance, 7, 174-180.
10 TPM Elsev 5s Improve [7]. Aradhye, A. S., & Kallurkar, S. P. (2014). A Case
implementation ier Kaizen performa
in a machine nce Study of Just-In-Time System in Service
shop. case efficienc Industry. Procedia Engineering, 97, 2232-2237.
study y and [8]. Naufal, A., Jaffar, A., Yusoff, N., & Hayati, N.
reduce (2012). Development of Kanban system at local
break manufacturing company in Malaysia–case
down
time study. Procedia Engineering, 41, 1721-1726.
[9]. Rohani, J. M., & Zahraee, S. M. (2015). Production
IV. CONCLUSION line analysis via value stream mapping: A lean
manufacturing process of color industry. Procedia
Implementation of lean manufacturing is mainly useful Manufacturing, 2, 6-10.
for waste reduction, continuous improvement, process [10]. Singh, R., Gohil, A. M., Shah, D. B., & Desai, S.
improvement and improving supplier customer (2013). Total Productive Maintenance (TPM)
relationship by reducing lead time. It is also offers implementation in a machine shop: A case
various types of tools to improve manufacturing. Adding study. Procedia Engineering, 51, 592-599.
that, lean manufacturing also provides varieties of
strategies for improving performance and to compete in
this emerging market.

V. REFERENCES

[1]. Haefner, B., Kraemer, A., Stauss, T., & Lanza, G.

(2014). Quality value stream mapping. Procedia
CIRP, 17, 254-259.
[2]. Rahani, A. R., & Al-Ashraf, M. (2012). Production
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[3]. Antony, J., & Desai, D. A. (2009). Assessing the
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