IMPLIMENTING LEAN TOOL

Shri G.S.Institute of technology and science IndoreProcess
(M.P.)Number of Employees
252500-1400
MarchNumber of Suppliers
200920
IMPLIMENTING LEAN TOOL JET IN GEARRESEARCH METHODOLOGY:
MANUFACTURING COMPANY Initially the general information of the company is
A STUDYaccessed from the website of the company.
Prabhat Kumar, Ajay VermaSubsequently the detailed information is available from
 the plant visit. The information obtained during
 discussion with, managers, production in charge,
Shri G.S.Institute of technology and science Indoresupervisors, workers, etc. Information is collected
(M.P.)regarding the identifying area, which include system of
 5s, kaizen, JIT, Quality management. The information
- A STUDYwas made available through company records,
 documents etc.
IMPLIMENTING LEAN TOOL JET IN GEARJIT IMPLEMENTATION:
MANUFACTURING COMPANY- A STUDYIn many industrial processes, such “non-value
*Prabhat Kumaradded” activity can comprise more the 90%of the
 total activity as a result of time spent waiting,
 Abstractunnecessary “touches" of the product,
 Lean manufacturing concepts to the continuousoverproduction wasted movement, and  insufficient
production process sector with a focus on Gearuse of raw materials, energy, and other factors. The
manufacturing company. The concept of the ToyotaCase Study addresses the application of lean
Production System or what is known today in the USmanufacturing concept to the continuous production
as “Lean Manufacturing.” The basic idea behindprocess sector with a focus on the process industry. In
the system is eliminating waste .Waste is defined asthe company following main waste that is reduce by
anything that does not add value to the product fromlean tool Just in time.
the customer’s perspective. The primary objective1. Overproduction – In Industry the reasons of the
of lean manufacturing is to assist manufacturers whooverproduction is poor flow of information, and
have a desire to improve their company’smanagement also want to engage the worker for
operations and become more competitive through theproduction, and also Lack of stable schedules.
implementation of different lean manufacturing tools1. 2. Delays (waiting time) – The main reason of
and techniques.Delay is Machine breakdowns. In Gear industry the
The company believes in total customer satisfactionBroaching Rod breakdown is Common the reason is
through open communication, quality up-gradation andnot proper maintenance and machine is old style, that
continuous training, the practice of which will lead it tothe reason of many time Delay. Many times the file
being recognized as a World Class Gearthat is required for production is missing in production
Manufacturer. Industry is the largest manufacturer ofplanning department. For that problem Searching for
automobile transmission gears in India boasting strengthfiles or documents will cause waiting time. A simple
of over 1000 trained and committed employees andtrick will help: draw a colored slant line on the back of
offering a range of around 1700 gears for virtuallythe files:  
every major brand of truck, car, jeep, and tractor. This3. Transportation-In gears industry due to reason of
dissertation is based on data based analysis. We arethe Plant layout it can not be reduce but they have to
used one tool six sigma and another kaizen from leanbe kept to the very minimum.
manufacturing.4. Process - In Gears Industry Old rules still remain
KEY WORD: Six sigma, DAMIC, DMADV, Kizen,even if the causes of their creation disappeared a
Kanban, 5Swhile ago. As long as nobody will update the set of
 rules, everyone will carry on, sticking to the olds with
*Prabhat Kumar, M.E, 3rd Semester, Industrialapplication and discipline.
Engineering and Management5. Inventories- That type of west are not found in
   Shri G.S.Institute of technology and science IndoreGear industry  they achieve only a standard level
(M.P.)inventory only.
   Introduction6. Defective products- Rejection and rework due to
Running the company as efficiently as possible hasTeeth Span Size Variation of GG 1491/1 after Shaving.
become critical in recent years. In today’s due toThat Type of waste reduces by Use the lean tool six
reason of competitive market various continuoussigma in the case study.
improvement strategies have been developed and7. Mis-used Resources
applied to improve manufacturing system performance 
over the year. 
U.S. manufacturers have always searched for 
efficiency strategies that help reduce costs, improve 
output, establish competitive position, and increase 
market share. Early process oriented mass production 
manufacturing methods common before World War II 
shifted afterwards to the results-oriented, 
output-focused, production systems that control most 
of today's manufacturing businesses. After World War 
II Japanese, manufactures were faced with the 
dilemma of vast shortages of material, financial, and 
human resources. The problems that Japanese 
manufacturers were faced with differed from those 
of their Western counterparts. These conditions 
resulted in the birth of the “lean” manufacturing 
concept. Lean Manufacturing initiative focused on cost                        References
reduction and increase in turnover by systematically [1] A.Rehg, James and W. Kraebber, computer
and continuously eliminating non value added activities.integrated Manufacturing,
This research addresses the application of lean      Second edition pp295
manufacturing tool in gear manufacturing company to[2]. Book A. Stephen & Epstem J. Mare, Statical
improve the product quality and total customerAnalysis,
satisfaction. In that time customer want satisfactory      Scott Foresman Company, Genavew,
quality with minimum cost and cost of product ispp-38-77
minimize with the help of waste minimization, waste is[3].Bank Johan, Total Quality Management, Hall of India
that does not add any value.private limited
Basic Tool of implementing Lean        Publication pp-21-51
Tool of implementing the lean is depend on the nature[4]. Dr. Trukes H.E., Design for Economical production,
of industry and their requirement but there are five2nd edition, pp285-288
basic steps in assessing lean tool:[5]. Griffiths N. David, Management in A Quality
1.5sEnivermaent,
2. Kizen       Mc Grawa Hill, pp21-23
3. Kanban[6]. Jhamb L.C., Production (Operations) Management,
4. Jit       Everast Publication, pp615-627
5. Six sigma[7].Josep H.S. Martinich, Production & Operation
Case StudyManagement,
The company started in 1950. Originally trading in diesel      John Wiley & Sons, Inc. 1997 pp-758-761
engines and spares, it then moved on to making Gears[8].Khan M.I Industrial Engineering, New Age International
in 1962 with the set up of Gajra Gears. Currently GajraPublications, pp 178-181
Gears is the largest manufacturer of automobile[9].Mahapatra P.B, Computer Aided Production
transmission gears in India boasting strength of overManagement ,
1000 trained and committed employees and offering a      Prentice   Hall Of India Pvt. Limit. New Delhi,
range of around 1700 gears for virtually every major2001,pp461-510
brand of truck, car, jeep, and tractor. Keeping pace[10]. Michael L. George, Dave Rowlands, Bill Kastle,
with the gear industry's ever-evolving needs Gajra‘’what is Lean Six
Gears over the years has further extended its         Sigma?’’Published by
capabilities to cater to railway, off road and other nicheMcGraw-Hill Professional, 2003, pp7-9.
segments of gear application. Although initially[11]. Raju S.M., Sundra, Total Quality Management,
concentrating on the Indian aftermarket, today more       Tata Mc Grawa Hill, 2003, pp13-18
than 50% of the products manufactured at Gajra[12].Telsang Martand, Industrial Engineering and
Gears are exported across the globe. General profileProduction Management,
of the company under study is shown in Table (1).         S.Chand & company ltd., 2006,
Table 1: General Profile of Companypp426-433
 [13].Zaidi A, SPC Concepts, Methodology & Tools,
Type of  CompanyPHI Publication, pp307-314
Private Limited[14].Indian Journal Of Marketing, Number-11, Nov.2008,pp
Nature of company40
Medium scale[15].Udyog Pragati, Vol.-29, No.-3, July to September,
Type of production systempp25
Make to order 
Product being manufacturedWebsite
1.Transmission Gears1. [16] browsed on 8/12/2008 
2. Spline Shafts and Axles[17] browsed on 8/12/2008
3. Engine Gears, Oil Pump Gears[18] Browsed on 6/12/2008
4. A Gear Box Assemblies [19]
5.Automatoic Transmission Parts         Browsed on5/12/2008
7. Planetary Assemblies.[20] browesd on 4/12/2008
Sales Turnover[21] browesd on 3/12/2008
Near 98 crores[22]
Type of layout       /lean/02tch-mtctw.