Analysis of lean manufacturing in an automobile industry - a case study

The automobile industries are more competitive and customer demand is volatile. The customers are willing to buy the product at low cost with high quality. So common principle is created to reduce the wastage and increase the efficiency of the industry. Lean manufacturing is the best principle to adopt the manufacturing industry. The main aim of this project is reduce the wastage, cost and increase the productivity of the industry. Using lean tools just in time (JIT), kanban, value stream mapping (current and future state) and man machine chart (current and future) for reduce wastage and cost. In current state value stream map, the waste area is identified. Finally, non-value added time is reduced to 28.7%. The value added time is reduced to 27.84%. The percentage value addition is increased from 3.25% to 3.29%, the total inventory is reduced to 25.07% and man machine ratio is improved as 1.52: 1.26.