International Research Journal of Engineering and Technology (IRJET)
e-ISSN: 2395-0056
Volume: 10 Issue: 05 | May 2023
p-ISSN: 2395-0072
www.irjet.net
PRODUCTIVITY IMPROVEMENT USING LEAN TOOLS IN PUMP INDUSTRY A.NAGARAJ1, M.SARAVANAKUMAR2, A.HARDY KELVIN 3, V.KUMARESAN 4, S.MADHAVASELVAN 5, S.VISHAL 6 , Dept. of Mechanical Engineering, PSG Polytechnic College, Tamil Nadu, India
1,2 Lecturer
3,4,5,6 Students, Dept. of Mechanical Engineering, PSG Polytechnic College, Tamil Nadu, India
---------------------------------------------------------------------***--------------------------------------------------------------------1.1 Implementation of lean manufacturing steps
Abstract - In its most basic form, lean manufacturing is
the systematic elimination of waste from all aspects of an organization's operations, where waste is viewed as any use or loss of resources that does not lead directly to creating the product or service a customer wants when they want it. In many industrial processes, such non-value-added activity can comprise more than 90 percent of a factory's total activity. Nationwide, numerous companies of varying size across multiple industry sectors, primarily in the manufacturing and service sectors are implementing such lean production systems, and experts report that the rate of lean adoption is accelerating. Companies primarily choose to engage in lean manufacturing for three reasons: to reduce production resource requirements and costs; to increase customer responsiveness; and to improve product quality, all which combine to boost company profits and competitiveness.
1. Waste identification in the system:Many organisations must be aware that their systems contain several hidden and unhidden wastes. 2. Wastes in the organisation might be of various types: The types of trash and their causes must be identified. Lean manufacturing believes in addressing the root causes of problems and permanently resolving them. There are numerous tools and techniques that can be used to reduce or eliminate this form of waste. 3. The next stage is to identify and address the underlying causes:- Stick to core lean concepts and look for root reasons. Looking at causes may not be sufficient, hence it is necessary to discover the effects of the causes solution on the entire system..
Key Words: Waste, Industry sector, Productivity improvement
4. The final step in the lean implementation process is to identify and test solutions:- After testing, solutions should be implemented. Training and follow-up are critical in each of the steps outlined above. It is necessary to be patient because the implementation process may take some time.
1.INTRODUCTION The Toyota Production System (TPS), pioneered by a Japanese automobile corporation, Toyota, has been adopted by practically every country in the world due to its global superiority in cost, quality, flexibility, and quick response. Lean is a manufacturing practise that tries to reduce waste across whole value streams in order to provide greater value to consumers. It is a customercentric strategy that focuses on the value stream and its optimisation. The utilisation of resources that do not provide customer value is a target for reform or elimination under lean principles.
1.2 Waste Types The following are the seven types of waste: (1) Overproduction: It is unnecessary to manufacture more than the consumer requires, or to make it too soon before it is required. This increases the chances of obsolescence and creating the wrong thing. It frequently results in high lead and storage durations.
The primary goal of implementing lean manufacturing is to increase production, reduce lead time and cost, and improve quality in order to provide the maximum value to customers. There are numerous descriptions regrading lean manufacturing in the industries.
© 2023, IRJET
|
Impact Factor value: 8.226
(2) Defects: In addition to physical flaws that directly contribute to the Costs of goods sold, which may include documentation errors, late delivery, production to inaccurate specifications, the use of excessive raw materials, or the development of unneeded scrap. Rework may be required if a flaw arises; otherwise, the product would be discarded. Defects not only waste material and human resources, but they also cause material shortages, interfere with achieving deadlines, create idle time at
|
ISO 9001:2008 Certified Journal
|
Page 1312