Implementation of lean manufacturing and lean audit system in an auto parts manufacturing industry – an industrial case study

Lean manufacturing is one of the innovative manufacturing concepts being applied in many industries to avoid the wastages of resources and improving the quality of products and help the company to become more effective and productive. It also focuses on continuous improvements with the total involvement of all employees with optimum utilization of man power and machine by reducing idle time and reducing lead time with help of lean tools like value stream mapping and kaizen. This paper presents a case study carried out in a foundry division of an auto parts manufacturing industry, where lean tools are implemented for the defect reduction and productivity improvement. In this paper, a conceptualized implementation of total productive maintenance practices of lean tools: Kaizen or continuous improvement and value stream map in an auto parts industry are presented. The result shows improved performance in terms of average core rejections, sand leakage and air lock problem.