Skip to main content
Top

2021 | OriginalPaper | Chapter

Rejection Minimization Through Lean Tools in Assembly Line of an Automotive Industry

Authors : Rakesh Giri, Ashok Kumar Mishra

Published in: Advances in Industrial and Production Engineering

Publisher: Springer Singapore

Activate our intelligent search to find suitable subject content or patents.

search-config
loading …

Abstract

In order to compete in the ‘Automotive Industry’ which is the world’s largest manufacturing industry, manufacturing managers have to put their efforts in motivating their personnel to increase their efficiency and improve the processes to achieve a common successful goal of improved productivity and quality. In this research, focus has been made to reduce the MUDA work elements associated with the activities in manufacturing cycle at different workstations on the line by using some advanced methods and tools, which have characteristics to prevent or trace the fault in the very beginning of its occurrence. In context of the above, focus has been made to implement the Lean Concepts (Kaizen, 5S and Poka-yoke) to improve the productivity and quality of its product by reducing cycle time, lead time and rejection. In this research, the five steps of DMAIC cycle has been used to synchronize the findings and their effects throughout the manufacturing cycle. The results indicate that after implementing the lean components integrated with DMAIC cycle, productivity has improved, and rejection reduces to Zero from 0.8% at illumination testing station in assembly line of HVAC Switch.

Dont have a licence yet? Then find out more about our products and how to get one now:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

  • über 102.000 Bücher
  • über 537 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Finance + Banking
  • Management + Führung
  • Marketing + Vertrieb
  • Maschinenbau + Werkstoffe
  • Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

  • über 67.000 Bücher
  • über 390 Zeitschriften

aus folgenden Fachgebieten:

  • Automobil + Motoren
  • Bauwesen + Immobilien
  • Business IT + Informatik
  • Elektrotechnik + Elektronik
  • Energie + Nachhaltigkeit
  • Maschinenbau + Werkstoffe




 

Jetzt Wissensvorsprung sichern!

Literature
1.
go back to reference Warnecke, H.J., Huser, M.: Lean production. Int. J. Prod. Econ. 41, 37–43 (1995)CrossRef Warnecke, H.J., Huser, M.: Lean production. Int. J. Prod. Econ. 41, 37–43 (1995)CrossRef
2.
go back to reference Braiden, B.W., Morrison, K.R.: Lean manufacturing optimization of automotive motor compartment system. Computer Ind. Eng. 31(1/2), 99–102 (1996)CrossRef Braiden, B.W., Morrison, K.R.: Lean manufacturing optimization of automotive motor compartment system. Computer Ind. Eng. 31(1/2), 99–102 (1996)CrossRef
3.
go back to reference Holweg, M.: The genealogy of lean production. J. Oper. Manage. 25, 420–437 (2007)CrossRef Holweg, M.: The genealogy of lean production. J. Oper. Manage. 25, 420–437 (2007)CrossRef
4.
go back to reference Herron, C., Hicks, C.: The transfer of selected lean manufacturing techniques from Japanese automotive manufacturing into general manufacturing (UK) through changes agents. Robot. Comput. Integr. Manuf. 24, 524–531 (2008)CrossRef Herron, C., Hicks, C.: The transfer of selected lean manufacturing techniques from Japanese automotive manufacturing into general manufacturing (UK) through changes agents. Robot. Comput. Integr. Manuf. 24, 524–531 (2008)CrossRef
5.
go back to reference Sun, X. F., Cheng, G., Li, W.: Work improvement in a packaging machine manufacturing company, a case study. Int. Conf. Indus. Eng. Indus. Manag. (2009) Sun, X. F., Cheng, G., Li, W.: Work improvement in a packaging machine manufacturing company, a case study. Int. Conf. Indus. Eng. Indus. Manag. (2009)
6.
go back to reference Pool, A., Wijngaard, J., van der Zee, D.-J.: “Lean planning in the semi-process industry”, a case study. Int. J. Prod. Econ. 131, 194–203 (2011)CrossRef Pool, A., Wijngaard, J., van der Zee, D.-J.: “Lean planning in the semi-process industry”, a case study. Int. J. Prod. Econ. 131, 194–203 (2011)CrossRef
7.
go back to reference Demeter, K., Matyusz, Z.: The impact of lean practices on inventory turnover. Int. J. Prod. Econ. 133, 154–163 (2011) Demeter, K., Matyusz, Z.: The impact of lean practices on inventory turnover. Int. J. Prod. Econ. 133, 154–163 (2011)
8.
go back to reference Romero-Sanchez, J., Martinez-Vilchez, R., Galvez-Zarate, C., Raymundo-Ibanez, C.: Process management model in dry cleaning and fabric finishes applying Lean manufacturing and Kaizen matrix for the textile sector., 978–1–7281–0883–4/19, IEEE (2019) Romero-Sanchez, J., Martinez-Vilchez, R., Galvez-Zarate, C., Raymundo-Ibanez, C.: Process management model in dry cleaning and fabric finishes applying Lean manufacturing and Kaizen matrix for the textile sector., 978–1–7281–0883–4/19, IEEE (2019)
9.
go back to reference Bazan-Rios, K., Chavez-Canales, C., Ramos-Palomino, E., Eyzaguirre-Munarriz, J., Mesia, R.: An integrated system: Lean, Six Sigma and theory of constrains, a study applied in wooden furniture industry in Lima, Peru. In: 2019 7th International Engineering, Sciences and Technology Conference (IESTEC) Bazan-Rios, K., Chavez-Canales, C., Ramos-Palomino, E., Eyzaguirre-Munarriz, J., Mesia, R.: An integrated system: Lean, Six Sigma and theory of constrains, a study applied in wooden furniture industry in Lima, Peru. In: 2019 7th International Engineering, Sciences and Technology Conference (IESTEC)
10.
go back to reference Ghobadian, A., Talavera, I., Bhattacharya, A., Kumar, V., Garza-Reyes, J.A., O’ Regan, N.: Examining legitimatization of additive manufacturing in the interplay between innovation, lean manufacturing and sustainability. Int. J. Prod. Econ. 219, 457–458 (2020) Ghobadian, A., Talavera, I., Bhattacharya, A., Kumar, V., Garza-Reyes, J.A., O’ Regan, N.: Examining legitimatization of additive manufacturing in the interplay between innovation, lean manufacturing and sustainability. Int. J. Prod. Econ. 219, 457–458 (2020)
11.
go back to reference Kumar, B., Rakesh, P.K.: Implementation of Poka Yoke in needle bearing assembly process. Int. J. Eng. Sci. Invention. ISSN (Online): 2319–6734, vol. 6 Issue 11|, November 2017, PP 01–10 Kumar, B., Rakesh, P.K.: Implementation of Poka Yoke in needle bearing assembly process. Int. J. Eng. Sci. Invention. ISSN (Online): 2319–6734, vol. 6 Issue 11|, November 2017, PP 01–10
12.
go back to reference Premanand, N., Kannan, V., Sangeetha, P., Umamaheswari.: A study on implementation of poka– yoke technique in improving the operational performance by reducing the rejection rate in the assembly line. Int. J. Pure Appl. Math. 119(17), . 2177–2191 (2018). ISSN: 1314–3395 Premanand, N., Kannan, V., Sangeetha, P., Umamaheswari.: A study on implementation of poka– yoke technique in improving the operational performance by reducing the rejection rate in the assembly line. Int. J. Pure Appl. Math. 119(17), . 2177–2191 (2018). ISSN: 1314–3395
Metadata
Title
Rejection Minimization Through Lean Tools in Assembly Line of an Automotive Industry
Authors
Rakesh Giri
Ashok Kumar Mishra
Copyright Year
2021
Publisher
Springer Singapore
DOI
https://doi.org/10.1007/978-981-33-4320-7_24

Premium Partners