The document outlines lean manufacturing principles in the automobile industry, focusing on waste elimination and improving efficiency. It discusses various types of waste, including overproduction, motion, over-processing, transportation, and inventory, along with strategies to mitigate them. Key examples of companies implementing lean manufacturing include Toyota, Ford, Chrysler, Porsche, and General Motors.

1. LEAN MANUFACTURING
IN AUTOMOBILE
INDUSTRY
Anuj Shah
Vth sem, Automobile
Parul Institute Of technology

2. INTRODUCTION
 Lean manufacturing, is a systematic method for the elimination of
waste (“MUDA") within a manufacturing process. Lean also takes into
account waste created through overburden (“MURI") and waste
created through unevenness in work loads (“MURA").

3. TYPES OF WASTE

4. The two pillars of LEAN MANUFACTURING. Lean implementation is therefore focused on getting the
right things to the right place at the right time in the right quantity to achieve perfect work flow,
while minimizing waste and being flexible and able to change. These concepts of flexibility and
change are principally required to allow production leveling also know as HEIJUNKA.
LEAN
MANUFACTURING
JUST IN TIME AUTONOMATION

5. Lean goals and strategy
 Improve quality
 Eliminate waste
 Reduce time
 Reduce total costs

6. THE 5’S OF LEAN MANUFACTURING
 Much of Lean manufacturing is applying “common sense” to
manufacturing environments. In implementing Lean, 5 S’s are
frequently used to assist in the organization of manufacturing. The 5
S’s are from Japanesse and are:
 Seiri (sort)
 Seiton (set-in-order)
 Seison (cleanliness)
 Seiketsu (standardize)
 Shitsuke (discipline)

7. LEAN MANUFACTURING
IN
AUTOMOTIVE INDUSTRY

8. ELIMINATION OF WASTAGE,OVERLOAD AND
UNEVENESS
 Wastage in production( Muda)-
 Motion:- Work smart not hard
Wastage of motion is any motion of man
and/or equipment that does not add value
to the product or service.
Wasteful motion can be over come by :-
1)Effective workstation layout, reduces excessive
Walking , bending and reaching while working.
2)Well designed method, locating car parts where they a
Are needed.
3)Small batch size, each batch for special and
specific part or process.

9. Over Processing
 Over processing is putting more into the product
then is valued by customers
1)Painting of unseen and unrequired areas.
2)Cleaning and polishing beyond the point required
3)Add-on instrument in cars that are not required
Over –Processing can be over come by:-
1)Standardizing of best techniques
2)Clear specification/quality acceptance standards.
3) Computerised robots for special purpose for even
working and avoid over processing.
The goal is to do only the level of processing to match
that which is necessary and useful.

10. Over Production
 Over production is the worst kind of waste because it causes
other wastes and obscures the need of improvement.
 Over production waste results from producing more than required.
 Over production can be over come by :-
1) Analysing market
2) Demand Of Cars
3) Forecasting of car requirement in certain market in upcoming
month.
4) Stable schedules.
5) Balanced cells and department

11. Transportation
 Transportation waste is material movement that is
not directly associated with the value adding process.
 Process should be close together as possible and
material flow directly from process without any significant
delays in between.
 Transportation loss can be over come by :-
1)Using multi purpose transportation layout, which delivers
the parts and product with full capacity.
2) Minimising the distance between different level i.e. Primary,
secondary and Tertiary industry.
3) Working faster then the demand.

12. Inventory
 Inventory waste is stock and work in process in excess
of the requirements necessary to produce goods or services
‘Just In Time’.
 Unnecessary inventory that accumulates before or after
a process is an indication that continuous flow is not being
achieved .
 In automobile industry the waste of inventory can be
overcome by:-
1) Proper management of required parts.
2) Achieving effect procedure to assemble the parts.
3) Balancing of work at different stages of assembly.
4) Using of comprised monitored, stock system. Which track the
Requirement of the stock

13. Automobile manufacturers using Lean
Manufacturing
 Toyota Motor Company, Toyota Production System
 Ford Motor Company ,The Ford Production System
 Chrysler ,Chrysler Operating System
 Porsche ,The Porsche Improvement Process
 General Motors ,NUMMI joint venture with Toyota

14. THANK YOU