Minimizing in-Process Inventory and Labour Movements: A Lean Approach

This research focuses on optimizing manufacturing processes within the Tillers and Tractors manufacturing industry, specifically addressing the challenges faced in producing crankshafts. The initial assessment revealed that the company struggled to meet customer demand due to an extensive manufacturing lead time. To tackle these inefficiencies, lean manufacturing principles were applied, targeting the elimination of non value added activities such as overproduction, excessive waiting times, unnecessary material transport, defects, and underutilization of employee creativity. The implementation of a lean manufacturing system, including the redesign of the plant layout and value stream mapping, aimed to streamline the production process. The proposed changes significantly reduced material movement and optimized workflow within the manufacturing cell. The primary outcome of this research is the development of an efficient plan to achieve line balance and reduce process cycle times, ensuring the company can meet customer demand in a timely manner. By minimizing machine and labour movements and promoting multitasking on the shop floor, the proposed solutions contribute to enhanced productivity and a decrease in in-process inventory, ultimately improving the operational flexibility and responsiveness of the manufacturing system.