An exhaustive case study of Lean Manufacturing

DEPARTMENT OF MECHANICAL ENGINEEERING SRMGPC CERTIFICATE

Certified that project entitled An exhaustive case study of Lean Manufacturing submitted by Animesh Pratap Singh (Unv. Roll No. 0712240010), in the partial fulfillment of the requirement for the award of the degree Bachelor of Technology (Mechanical Engineering) of G.B. Technical University, is a record of students own work carried under my supervision and guidance. The project report embodies result of referred work and studies carried out by students and the content do not form the basis for the award of any other degree to the candidates or to any body else.

Prof. D.V. Mahendru (Project Guide)

Prof. A.K. Srivastava Head (Mechanical Engineering) SRMGPC

ME DEPARTMENT, SRMGPC, Lucknow

An exhaustive case study of Lean Manufacturing

DEPARTMENT OF MECHANICAL ENGINEEERING SRMGPC DECLARATION

We hereby declare that the project entitled An exhaustive case study of Lean Manufacturing submitted by Animesh Pratap Singh (Unv. Roll No. 0712240010) in the partial fulfillment of the requirement for the award of the degree Bachelor of Technology (Mechanical Engineering) of G.B. Technical University, is a record of students own work carried under supervision and guidance PROF. A.K. SRIVASTAVA (HOD ME DEPARTMENT). To the best of our knowledge this project has not been submitted to G.B. Technical University or any other University or Institution for the award of any degree.

Animesh Pratap Singh (0712240010)

ME DEPARTMENT, SRMGPC, Lucknow

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An exhaustive case study of Lean Manufacturing

ACKNOWLEDGEMENT
We feel very much privileged to acknowledge the contribution of all that have been inspirational and supportive through our project report on An exhaustive case study of Lean Manufacturing. For this project report information has been collected from two sources, books and internet. We would like to express our gratitude to the persons who have provided their research papers on the web pages. It is our privilege to extend our deep sense of gratitude and thanks to our HOD (ME Dept.) (PROF. A.K. Srivastava) and our Project Guide (Prof. D. V. Mahendru) for encouraging us all the time and providing us all the valuable facilities required for the completion of this project report. We are thankful to all non teaching staff members specially lab assistants for their support and help to complete this project report. Last but not the least; we would like to thank the almighty for blessing us with strength to face any situation with courage in life.

Animesh Pratap Singh (0712240010) B.Tech (Mechanical Engineering) 4th year

ME DEPARTMENT, SRMGPC, Lucknow

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An exhaustive case study of Lean Manufacturing

PREFACE

The present report attempts to describe Lean Manufacturing in a unified way. The language of the report is fairly mathematical. However, the mathematical knowledge of anyone, who has followed at least two years of a course on mathematics, physics, or chemistry at university level, should amply suffice in order to follow the calculations. The report does not contain a single differential equation! Also, the physics background needed is of undergraduate level. We therefore hope the report will appeal to a broad public. However, the reader should be familiar with SI units, which are used throughout the report. The following people are thanked for their direct help with the accomplishment of the manuscript: 1. Mr. Dinesh (Lecturer in S.R.M.G.P.C) 2. Mr. A.K.Garg (Workshop Superintendent in S.R.M.G.P.C) 3. Mr. Mukesh (Lab Technician in S.R.M.G.P.C) 4. Mr. Ravi Gupta(Lab Assistant in S.R.M.G.P.C)

ME DEPARTMENT, SRMGPC, Lucknow

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An exhaustive case study of Lean Manufacturing

ABSTRACT

Lean focuses on abolishing or reducing wastes (or muda, the Japanese word for waste) and on maximizing or fully utilizing activities that add value from the customers perspective. From the customers perspective, value is equivalent to anything that the customer is willing to pay for in a product or the service that follows. So the elimination of waste is the basic principle of lean manufacturing. Our study shall concentrate on systematical demonstration of how lean manufacturing tools when used appropriately can help the process industry to eliminate waste, have better inventory control, better product quality, and better overall financial and operational procedures applying the Lean Management in the workshop of S.R.M.G.P.C.

ME DEPARTMENT, SRMGPC, Lucknow

An exhaustive case study of Lean Manufacturing

TABLE OF CONTENTS
S.No. Certification Declaration Acknowledgement Preface Abstract Table of contents Chapter 1 Introduction 1.1 Back ground 1.2 Problem Statement 1.3 Problem Objective 1.4 Project Approach Chapter 2 Literature Review 2.1 History Of Lean 2.2 What is Lean Manufacturing 2.3 What is Lean Chapter 3 Tools and Techniques of Lean Manufacturing 3.1 Cellular Manufacturing 3.2 Kaizen (Continuous Improvement) 3.3 Standardization of Work 3.4 Total Productive Maintenance 3.5 5 S 3.5.1 Introduction 3.5.2 Method and Implementation Approach 3.5.3 The 5S Pillars
ME DEPARTMENT, SRMGPC, Lucknow

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An exhaustive case study of Lean Manufacturing

3.5.3.1 Sort 3.5.3.2 Set In Order 3.5.3.3 Shine 3.5.3.4 Standardize 3.5.3.5 Sustain 3.5.4 Potential Benefits 3.5.5 Potential Shortcomings 3.6 From Lean Manufacturing to Lean Enterprise 3.6.1 Value adding activities 3.6.2 Necessary non-value adding activities 3.6.3 Unnecessary non-value adding activities 3.7 Supply Chain Management Chapter 4 Application of Lean in the workshop of S.R.M.G.P.C. 4.1 Red Tagging 4.2 Kaizen Sheets Chapter 5 Results APPENDICES APPENDIX-A APPENDIX-B Chapter 6 References

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ME DEPARTMENT, SRMGPC, Lucknow

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An exhaustive case study of Lean Manufacturing

APPENDIX A LIST OF FIGURES

Description of Figure

Page No.

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Fig 3.1: Kaizen Diagram Fig 3.2: 5 S System Fig 3.3 5 S Working Fig 4.1: Red Tagging Fig 4.2: Red Tagging Fig 4.3: Red Tagging Fig 4.4: Red Tagging Fig 5.1: Site before Application of Lean Fig 5.2: Site before Application of Lean Fig 5.3: Site before Application of Lean Fig 5.4 Site before Application of Lean Fig 5.5 Site before Application of Lean Fig 5.6 Site after Application of Lean Fig 5.7 Site after Application of Lean Fig 5.8 Site after Application of Lean Fig 5.9 Site after Application of Lean Fig 5.10 Site after Application of Lean Fig 5.11 Site after Application of Lean Fig 5.12 Site after Application of Lean

15 17 23 27 27 27 27 51 51 51 51 51 52 52 52 52 53 53 53

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An exhaustive case study of Lean Manufacturing

APPENDIX-B LIST OF TABLES

Description of Table 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Table 1-TARGET ACHIEVEMENT SHEET for fist Kaizen sheet Table 2-TO DO STATISTICS for fist Kaizen sheet Table 4-TO DO STATISTICS for second Kaizen sheet Table 5- TARGET ACHIEVEMENT SHEET for third Kaizen sheet Table 6-TO DO STATISTICS for third Kaizen sheet Table 8--TO DO STATISTICS for fourth Kaizen sheet Table 9- TARGET ACHIEVEMENT SHEET for fifth Kaizen sheet Table 10-TO DO STATISTICS for fifth Kaizen sheet Page No. 30 31 36 40 40 44 48 48

Table 3- TARGET ACHIEVEMENT SHEET for second Kaizen sheet 35

Table 7- TARGET ACHIEVEMENT SHEET for fourth Kaizen sheet 44

ME DEPARTMENT, SRMGPC, Lucknow

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