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Lean Manufacturing Implementation - Case Study

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  • Dear Mr Palaniappan,

    Is it possible if I use two images from your presentation (slides 14 and 17) for my project on lean manufacturing?

    Kind regards,
    Kenneth
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  • 1. Case study from our Lean Manufacturing and 5S Implementation At India’s Largest footwear manufacturing company and its suppliers Visit our websites: www.hashllp.com www.businessense.in
  • 2. About us • At Business Sense, we help medium scale manufacturing units improve their operational efficiency through consulting engagements focusing on improving their Operations through Lean Manufacturing Implementation covering 5S, SMED, Kaizen and other tools • We promise to double the productivity in less than 33 days of our effort • In addition, our web application would help the senior management in monitoring the important business updates every day and provide them analytics and enable them better decision making. Useful if your organization do not have an ERP! • For more details, please visit www.businessense.in • You can subscribe to our bi-weekly newsletter here. • Follow us: (C) Property of Hash Management Services LLP 2
  • 3. Introduction to the case study • This case study is based on our work with one of India’s leading footwear manufacturer • A total of 25 days was spent by Hash Management Services LLP for the implementation of Lean Manufacturing (including 5S) • Significant improvements were observed in all the units in terms of – Higher productivity ( 30 to 50% improvement in Output) – More space creation – Removal of unwanted items from the shop floor – Reduction in mix-up and – Improved employee morale • Recognizing the benefits, client suggested us to cover Lean and 5S implementation in few other units also (C) Property of Hash Management Services LLP 3
  • 4. (C) Property of Hash Management Services LLP 4 All tools were randomly stored leading to searches and wastage in time Before 5S After 5S Tool rack was created in the central location of the shop floor. A smaller tool rack is also placed near the machine
  • 5. (C) Property of Hash Management Services LLP 5 Before 5S After 5S Excess dies were stored in the floor without identification Article-wise, size-wise storage of excess dies
  • 6. (C) Property of Hash Management Services LLP 6 Before 5S After 5S All stickers were stored in a bin. Difficult to retrieve and monitor quantity, more search and time involved Article-wise, Size-wise storage of stickers, eliminating search and monitor quantity
  • 7. After 5S : Color coding of dies, storage spaces, trolleys and bins throughout the company and its supplier units (C) Property of Hash Management Services LLP 7
  • 8. After 5S : Color coding of dies, storage spaces, trolleys and bins throughout the company and its supplier units (C) Property of Hash Management Services LLP 8
  • 9. Before 5S After 5S (C) Property of Hash Management Services LLP 9 Spares were not stored without identification All spares were counted, stored in racks with proper identification
  • 10. (C) Property of Hash Management Services LLP 10 Racks were numbered, with identification for all items
  • 11. A Set up trolley with wheels is created and can be moved near the machines during set up. (C) Property of Hash Management Services LLP 11
  • 12. Before 5S After 5S (C) Property of Hash Management Services LLP 12 Trimming wastes fall on the floor – needs separate cleaning Trimming wastes directly fall into a waste collection bag – easy cleaning Faces of people are blacked out for privacy reasons
  • 13. Batch Production processes leading to very high WIP (C) Property of Hash Management Services LLP 13
  • 14. Finishing happens during the last hour for delivery, leading to confusions (C) Property of Hash Management Services LLP 14
  • 15. Layout change to enable single pair flow – took 2 hours (C) Property of Hash Management Services LLP 15 Faces of people are blacked out for privacy reasons
  • 16. Layout to enable single pair flow (C) Property of Hash Management Services LLP 16 Faces of people are blacked out for privacy reasons
  • 17. Benefits of Single Pair Flow: Finishing activity happens everyday and all items produced on that day are packed on the same day. One entire room became free and is used to store finished goods (C) Property of Hash Management Services LLP 17
  • 18. Benefits (sent by the owner* of the company) (C) Property of Hash Management Services LLP 18 33% increase in Production 1.5 days * - Points may have grammatical errors. We have not edited the content sent by the clients
  • 19. Benefits (sent by the owner* of the company) (C) Property of Hash Management Services LLP 19 31% increase in Production 1.5 days* - Points may have grammatical errors. We have not edited the content sent by the clients
  • 20. Benefits (sent by the owner* of the company) (C) Property of Hash Management Services LLP 20 50% increase in Production 2 days * - Points may have grammatical errors. We have not edited the content sent by the clients
  • 21. Case study from our Lean Manufacturing and 5S Implementation At India’s Largest footwear manufacturing company and its suppliers Visit our websites: www.hashllp.com www.businessense.in

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