Abstract:
"Anything other than the minimum amount of equipment, materials, parts, space, and worker's time, which are absolutely essential to add value to the product is waste." These are the words of Mr Fujio Cho of Toyota Motor Corporation, Japan. Lean Manufacturing aims at complete elimination of waste. The apt definition of lean manufacturing can be given as: Lean manufacturing is a Business philosophy that continuously shortens the time between customer order and shipment by eliminating everything that increases the cost and time. The basis of lean manufacturing is Toyota production system which was followed in Toyota Motor Corporation, Japan. The focus at Toyota was the absolute elimination of waste, especially anything that prevented the most optimum flow and assembly of material, from raw material to finished goods. A fundamental waste seen at Toyota — and in every other anufacturing facility in the world — was the overproduction of larger batches than what was needed by the next operation. Lean manufacturing basically involves several types of principles and strategies, some of them commonly used in most of the enterprises. Apart from these several other strategies have been incorporated in most of the manufacturing setups only recently. In this paper presentation the various principles of lean manufacturing and the various benefits that the companies incorporating the 0lean techniques of production generally achieve has been discussed. In addition to these basics, an emphasis on concepts of “Just In Time” or JIT is also given. A case study has also been done on a rubber components manufacturing unit, situated at Mumbai, which incorporates lean manufacturing techniques.
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