Reduction of Wastages in Motor Manufacturing Industry

Lean manufacturing appears to hold considerable promise for addressing a range of simultaneous, competitive demandsincluding high levels of process and product quality, low cost and reductions in lead times. This research addresses theapplication of lean manufacturing concepts to the continuous production sector with a focus on the motor manufacturingindustry. The goal of this research is to investigate how lean manufacturing tools can be adapted from the discrete to thecontinuous manufacturing environment. This paper presents lean manufacturing as a leading manufacturing paradigmapplied in many sectors. The fundamental focus on lean production is the systematic elimination of non-value added activityand waste from the production process. The implementation of lean principles and methods results in improved system andsurrounding performance. Value stream mapping is used to first map the current state used to identify sources of waste andto identify lean tools to eliminate this waste. The future state map is then developed for a system with lean tools applied to it.To quantify the benefits gained from using lean tools and techniques in the value stream mapping, a detailed simulationmodel is developed and a designed experiment is used to analyze the outputs of the simulation model for different leanconfigurations. This paper demonstrates the implementation of lean philosophy through layout modification.