Implementation of lean E-AIR concepts for mass production motor assembly line

In mass production manufacturing industries, Lean manufacturing principles were used to improve the process efficiency by eliminating non value adding activities. In the conventional practice of lean manufacturing, only the practices of inventory control, JIT single piece flow, kanban tools are used. This paper is concerned with the implementation of lean principles as well as new methodology E-AIR (Eliminate, automate, integrate, re-engineering). Areas of improvement in the assembly lines are very high in mass production motor manufacturing industries; The Lean manufacturing will give the result of higher productivity, high degree of global (international) product quality with competitive cost benefit. In this paper, the Lean principles were applied to window lift motor assembly line and engine cooling fan motor assembly in order to manufacture the motors with optimum cycle time, increased productivity, higher degree of quality to meet international automotive standard and to exceed the customer expectations and needs.