• Save
A Study On the Effectiveness Of Lean Manufacturing Practices In MSME.
Upcoming SlideShare
Loading in...5
×
 

A Study On the Effectiveness Of Lean Manufacturing Practices In MSME.

on

  • 254 views

It is a study done on finding the Effectiveness of lean Manufacturing Practices In MSME (Micro Small Medium Enterprises) with the help of cluster approach. the Study has primarily been done on 33 ...

It is a study done on finding the Effectiveness of lean Manufacturing Practices In MSME (Micro Small Medium Enterprises) with the help of cluster approach. the Study has primarily been done on 33 industrial units in Mohali Chandigarh.This study is very necessary for the Engineering and as well as Business Students and Entrepreneurs for the implementation of Lean Manufacturing Practice. it gives the whole ideas of perception on Lean.

Statistics

Views

Total Views
254
Views on SlideShare
254
Embed Views
0

Actions

Likes
0
Downloads
0
Comments
1

0 Embeds 0

No embeds

Accessibility

Categories

Upload Details

Uploaded via as Microsoft PowerPoint

Usage Rights

© All Rights Reserved

Report content

Flagged as inappropriate Flag as inappropriate
Flag as inappropriate

Select your reason for flagging this presentation as inappropriate.

Cancel
  • Full Name Full Name Comment goes here.
    Are you sure you want to
    Your message goes here
    Processing…
  • hey guys do leave a comment on the ppt so that i can improve It in my Next upload. thanks heaps
    Are you sure you want to
    Your message goes here
    Processing…
Post Comment
Edit your comment

A Study On the Effectiveness Of Lean Manufacturing Practices In MSME. A Study On the Effectiveness Of Lean Manufacturing Practices In MSME. Presentation Transcript

  • Research Topic A Study on the effectiveness of lean Manufacturing Practices in Micro, Small and Medium Enterprises (MSME) through Cluster Approach Submitted by: Jaspreet Singh Uni. Roll No.:1176171 SID:- 0711-0027 1 A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • Introduction of Lean Manufacturing. A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach 2 • An operational system that maximizesValue Added, reduces Essential Support and eliminatesWaste in all processes • A good understanding of waste and value and a set of tools and techniques to eliminate the waste from system are very crucial to create a lean Enterprises. Tools of Lean 5S,Waste Identification & Elimination, Kaizen, S.M.E.D.(Single Minute Exchange Die), PokaYoke, Single Piece Flow,Value Stream Mapping , Visual Management.
  • Definition of Research Problem  “A study on the effectiveness of lean manufacturing practices in Micro, Small and Medium Enterprises (MSME) through cluster approach.”  The organizations were engaged in the Cluster Programme. Lean Manufacturing tools and technique were applied by them in their respective industries. 3 A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • Objective of the research.  To See the effectiveness of Lean Manufacturing practices?  What are the potential benefits been achieved by them?  Various factors responsible for the Adoption of Lean Manufacturing Practices ?  Reasons for being not be implemented in Some Industries? 4 A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • Designing of Research  Study is carried out in 33 industries, Who had implemented lean.  A key person was selected from each of these 33 industrial units for getting information on various aspects of the lean manufacturing practices and techniques.  Questionnaire was the tool used for collecting the data.  Data is analyzed through the SPSS, Micro soft Excel and some where manually too. 5 A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • Sampling design  Sample Size:- Sample Size was 33 industries , Concerned person was selected from those industries.  It was a Judgmental sampling technique. 6 A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • Measurement used  Mean  Variance  Standard deviation.  ANOVA’s  Chi-SquaredTest. 7 A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • Method adopted for data collection Method Adopted for Data Collection was a structured Questionnaire comprising the four sections as follows:  Perceptions about lean  Factors influence for adoption of the lean  potential benefits been achieved  Why it can not be implemented in some industries. 8 A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • Results. 9 How do you perceive the lean Manufacturing concept ? A Study on the effectiveness of lean Manufacturing Practices through Cluster Approach Table 1:- Mean score on different perceptions of the Lean Concept. Different Concept of lean Average of Responses receives. Improvement Project (I.P) 1.39 Complexity of technique (C.T) 3.52 Only a training Not Implementable 3.8 Piecemeal Approach (P.A.) 3.85 Time Waste Activities(T.A.) 4.36 1- Strongly Agree, 2- Agree, 3- neutral, 4- Disagree, 5- Strongly disagree. 1.39 3.52 3.8 3.85 4.36 0 1 2 3 4 5 I.P C.T N.I P.A T.A MeanRatingScale Industrial Perception About Diffrent Concept of Lean
  • 10 Factors responsible for adoption of lean manufacturing Practices in different types of industries. Table:-2 One wayVariance analysis had been done on the responses received. Factors Responsib le for lean Type of Industry Micro Scale Small scale Medium scale P.R.F. 3.99 4.12 3.875 C.D.F 4.22 4.22 4.167 P.F. 4.47 4.36 3.33 M.R.F. 4 4.2 3.5 3.99 4.22 4.47 44.12 4.216 4.36 4.2 3.875 4.167 3.33 3.5 0 1 2 3 4 5 P.R.F. C.D.F P.F. M.R.F. Micro scale Small scale Medium Scale 1- Strongly Disagree, 2- Disagree, 3- neutral, 4- agree, 5- Strongly agree. Lower Bound Upper Bound 1 21 3.9940 .32948 3.8441 4.1440 3.25 4.50 2 10 4.1250 .30619 3.9060 4.3440 3.63 4.50 3 2 3.8750 .17678 2.2867 5.4633 3.75 4.00 Total 33 4.0265 .31678 3.9142 4.1388 3.25 4.50 1 21 4.2302 .35542 4.0684 4.3919 3.33 4.83 2 10 4.2167 .43780 3.9035 4.5298 3.50 4.67 3 2 4.1667 .23570 2.0490 6.2844 4.00 4.33 Total 33 4.2222 .36720 4.0920 4.3524 3.33 4.83 1 21 4.4762 .65465 4.1782 4.7742 2.00 5.00 2 10 4.3667 .33148 4.1295 4.6038 3.67 5.00 Total 33 4.3737 .61100 4.1571 4.5904 2.00 5.00 1 21 4.0000 .70711 3.6781 4.3219 2.50 5.00 2 10 4.2000 .94868 3.5214 4.8786 2.50 5.00 Total 33 4.0303 .80951 3.7433 4.3173 2.50 5.00 N Mean Std. Deviation Maxim um prf cdf pf mrf 95% Confidence Interval for Mean Minimu m A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • 11 Which Tools and Techniques used by Companies? Tools used by companies No. of companies that used these tools 5S 32 W.I&E:- Waste identification and elimination 11 V.M.- Visual management 17 V.S.M- Value stream Mapping 0 T.P.M.- Total productive maintenance 1 S.M.E.D.- Single Minute exchange die. 26 Takt Time 0 S.P.F.- Single Piece flow 9 PokaYoke 7 Kaizen 33 Table:- 3 Shows that tools and techniques used by the Companies • Chi squared test were tried here. • Data received was not up to the expectation.So Chi-SquaredTest does not applied. A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • 12 Tools and Techniques used by Companies – Type of Industry wise. Tools/Techniques Type of industry. Micro scale Small scale Medium scale 5S 21 10 2 W.I.E 5 5 1 V.M 10 6 1 V.S.M 0 0 0 T.P.M 0 0 1 S.M.E.D. 13 11 2 T.T 0 0 0 S.P.F. 7 2 0 Q.F.D. 0 0 0 P.Y. 3 3 1 Kaizen 20 10 2 21 5 10 0 0 13 0 7 0 3 20 10 5 6 0 0 11 0 2 0 3 10 2 1 1 0 1 2 0 0 0 1 2 0 3 6 9 12 15 18 21 24 27 30 33 No.ofcompanies. Micro scale Small scale Medium scale This analysis had been done manually and graph is made with the help of Microsoft excel Table:- 4 Shows that tools and techniques used by the Companies A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • 13 What are the Potential benefit been obtained by Industries. Potential Benefits Mean of all response. Reduced Cost (R.C.) 3.06 Improved Service (I.S) 3 Improved On time Delivery (I.O.D) 3.09 Reduced Lead Time R.L.T. 3.3 Increase Manufacturing Flexibility (I.M.F.) 3.18 Zero Machine Breakdown (Z.M.B) 3.24 Improved Customer Service I.C.S 3.42 Eliminate Error Proofing (E.E.P) 2.73 1. Nil (0%), 2.Low (1-25%), 3.Moderate (26- 50%),4.High (51-75%), 5.Very High (75-100%) 3.06 3 3.09 3.3 3.18 3.24 3.42 2.73 1 2 3 4 5 r.c. I.S I.O.D R.L.T. I.M.F. Z.M.B I.C.S E.E.P ScaleOfbenefits. Potential Benefits. R.C- Reduced Cost, I.S- Improved Service, I.O.D. Improved In on time Delivery, R.L.T- Reduced Lead Time, I.M.F.- Improved Manufacturing Flexibility, Z.M.B.- Zero Machine Breakdown, I.C.S.- Improved Customer Satisfaction, E.E.P. – Eliminate the error Proofing. A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach Table:- 4 Shows the Benefits Obtained by Company.
  • Summary of Findings  Companies perceived lean manufacturing practice as an improvement project.  A negative trend can be seen on the negative perceptions of lean.  It was clearly found that, People related factors were the reasons for implementing the Lean Manufacturing practices  After people related factors customer driven factors is the second factor which is responsible for the adoption of lean manufacturing practices.  Customer driven factor was main reason for implementing the lean manufacturing practices in Medium scale industries.  5S and Kaizen had been implemented by all companies.  T.P.M. was implemented by only one company and that was a Medium scale company  Poka yoke was more used by small scale industries  Reduction cost was moderate (26-50%).  There was not any company who can get the higher benefits up to 90% in this research.  Error proofing was least beneficial than others.  58% people think that tools were complex for workers.  Entire Organization got benefits with the implementation.  They are recommending it to other companies to go for it too. 14A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • Limitations of the Research 15A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach •Due to certain reason only one person was selected from each industry as it can be more than one too. •The research was carried out in a short period of time. Therefore the sample size and other parameters were selected accordingly so as to finish the work within the time frame •This was the research from manufacturing sector as it may not be applied to service sector •The study was done only in Mohali
  • 16 Glimpses. Before After Before After AfterBefore A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach
  • Kaizen Sheet 1 6/21/2013 Kaizen No.773Productivity Quality 3M Safety Material Energy KaizenTheme :- Implemented Area :- Zone- 5 To increase the production of Upper chain bracket Implemented By:- Satpal Problem/Present Status:-- Before Implement:-- Result benefit: The production of upper chain bracket was low as there was a bit difficult to meet the monthly orders. P • Result production increased by 80%. • Saving Rs. 720 /day , which is Rs. 20540/ month. Q C D S M Root Cause Identification After Improvement:- Standardization:- The production of this part was low the fixture can only clamp these parts The fixture was small Root Cause: The fixture was small How many places this kaizen can be deployed horizontally: 9 Paces Found IdeaTo eliminate root cause The fixture can be enlarged Action taken The fixture modified. SOP to be revised Operation standard to be revised.
  • Thank you 18A Study on the effectiveness of Lean Manufacturing Practices In MSME through Cluster Approach