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

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.