Abstract:
Waste (non-value adding activities) reduction has become the focus point of every
industrynowadays and mentioning this brings up the ultimate solution, which is lean
manufacturingsystem.Thegoalofthispaperistoincreaseproductivityandproductionefficiency
byimplementation of leantools& techniques. Descriptive statistical analysis was usedwithmixed
qualitative and quantitative approaches. For this accomplishment, the required primarydata were
collected using observation, interviews and questioners by selecting 50 samples(operators) using
both random sampling method and stratified sampling. The analysis wasdone by firstly mapping
the existing stage of manufacturing and identifying the non-valueadding activities the selected
product family passes through, and secondly by using lean toolssuch as value stream mapping,
line balancing, total protective maintenance, and first-in first-out to reduce thewastesand for
production line improvement.The biggest improvementareas like excessive lead time, waiting
time, cycle time, and non-value adding time wereidentified. With these a new value stream
mapping was developed. After the
implementationoftheleantoolsandusingfuturestatevaluestreammappingmethod,thefuturestateprodu
ctionlineshowedaresultof34.7%reductioninproductionleadtime,29.02%reduction in waiting time,
39.4% reduction in cycle time, 29.01% reduction in non-valueadding activities. It was also
witnessed that line balancing and process cycle efficiencies wereincreased by 10.2 & 9.11%
respectively. This study concludes that, to minimize productionwaste of such production, lean
manufacturing has answered the research question and showedtheproductivityimprovementofthe
company.
Key words: lean manufacturing, lean tools, waste, value stream mapping, line
balancing,productivity.