Reducing Wastages in Pump Manufacturing Processes through Lean Manufacturing Concept

1S. Jeevabharathi

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Abstract:

Lean manufacturing is a systematic approach to process improvement. The method is based on finding and reducing waste coupled with continuous improvement. It was first developed by Toyota, but now applied to many diverse industries and businesses. An attempt has been made to apply lean manufacturing methodology in a leading pump manufacturing company, analyzing the seven wastages namely over-production, defects and their correction, inventory, transportation, waiting, motion and over-processing. The work concentrates on the activities in fettling, winding section, component stores and assembly section. To determine and reduce defects in winding section, Cause and effects diagram is constructed. Comparison is made on quality and productivity before and after implementing lean manufacturing. Proper transportation, material handling and storage systems are proposed to improve quality in fettling operations. Kanban cards are introduced to control the inventory level in stores, reducing the wastages.

Keywords:

Lean Manufacturing, Kanban Card, Visual Control, Standard Operating Procedure and Six-Sigma

Paper Details
Month5
Year2019
Volume23
IssueIssue 3
Pages168-182