Application of lean manufacturing in mass production system: A case study in Indian manufacturing unit

In the present competitive and challenging market, industries need to improve their performance by concentrating on their manufacturing processes. Lean manufacturing is one of the most powerful manufacturing control systems backed by several tools for improving quality, productivity and profitability, for eliminating waste and for improving process flow. Lean manufacturing can also help in environmental pollution control, cutting down the product cost, reducing physical effort and minimizing product manufacturing time. This paper illustrates the application of lean manufacturing to minimize the setup time, cycle time of a reputed manufacturing industry in India. A detailed description of each step of the process is given and is illustrated the results from a case study undertaken during the research. This article focuses on lean manufacturing tools like value stream mapping, method study, and its implementation. It will decrease the current lead time by fifty percent. It also proposes and comes out with measures to improve current operations within the company.