Application of Lean Manufacturing Using Kaizen Analysis: A Case Study

Authors

  • Amit Surya National Institute of Technology, Jalandhar, India
  • Rakesh Kumar National Institute of Technology, Jalandhar, India
  • Rajeev Trehan National Institute of Technology, Jalandhar, India

DOI:

https://doi.org/10.13052/jgeu0975-1416.1218

Keywords:

. Lean manufacturing, Root-cause analysis, Automotive industry

Abstract

Industrial production and operation have been completely transformed by lean methods made possible by lean management (LM) technologies in the industry. This paper investigates industry practices regarding the application of lean tools in the manufacturing sector. For the purpose of gathering data, a questionnaire survey was distributed among the manufacturing professionals in the organization where lean manufacturing has already been adopted. The purpose of the study is to highlight the perceived level of their contribution to operational performance. In order to access operational performance, the study uses lean tools such as root-cause analysis, kaizen hypothesis, and evaluation of kaizen hypothesis, as well as before and after comparison. The study confirms that widespread adoption of lean practices results in a decrease in setup time from 28 minutes to 6 minutes, an increase in productivity by 50 components per month, a reduction in average wheel damage, and average components being reworked.

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Author Biographies

Amit Surya, National Institute of Technology, Jalandhar, India

Amit Surya is a Ph.D. research scholar in industrial and production engineering department at National Institute of Technology, Jalandhar, Punjab, India. He has completed his Master of Technology in Production Engineering from Sant Longowal Institute of Technology, Sungrur, Punjab (India). He has completed his Bachelor of Technology in Mechanical Engineering from Punjab Technical University, Jalandhar. He has about 7 years of teaching experience. His research areas include, TPM, TQM, lean-six sigma.

Rakesh Kumar, National Institute of Technology, Jalandhar, India

Rakesh Kumar is a Associate Professor in industrial and production engineering department at National Institute of Technology, Jalandhar, Punjab, India. He has completed his Ph.D. in Mechanical and Industrial Engineering from Indian Institute of Technology, Roorkee. He has completed his Masters in Production Engineering from Punjab University, Chandigarh. He has completed his Master of Business Administration in Human Resource Management from Punjab Technical University, Jalandhar. He has completed his Bachelor of Engineering in Mechanical and Production Engineering from Annamalai University Tamil Nadu.

Rajeev Trehan, National Institute of Technology, Jalandhar, India

Rajeev Trehan is a Associate Professor in industrial and production engineering department at National Institute of Technology, Jalandhar, Punjab, India. He has completed his Ph.D. in Industrial Engineering from Dr. B.R. Ambedkar National Institute of Technology, Jalandhar. He has completed his Master of Technology in Industrial Engineering from Dr. B.R. Ambedkar National Institute of Technology, Jalandhar. He has completed his Bachelor of Technology in Mechanical Engineering from Dr. B.R. Ambedkar Regional Engineering College, Jalandhar.

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Published

2024-05-29

How to Cite

Surya, A., Kumar, R., & Trehan, R. (2024). Application of Lean Manufacturing Using Kaizen Analysis: A Case Study. Journal of Graphic Era University, 12(01), 125–146. https://doi.org/10.13052/jgeu0975-1416.1218

Issue

2024: Vol 12 Iss 1

Section

Articles