LEAN TOOL - SYSTEM BOUND

LEAN SYSTEM - A VALIANT VIALABLE TOOL FOR PRODUCTIVITY IMPROVEMENT TO LEATHER GOODS/ACCESSORIES MANUFACTURING

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The leather products manufacturing were bearing a major share in terms of foreign exchange for the country’s great volume of potential growth. The productivity improvement can help to enrich profit of the leather products manufacturing by a new method for a particular operation by reducing the excess work in terms of development. The productivity improvement is a prominent topic for all kinds of manufacturing. So improving productivity is one of the main concerns of leather products manufacturing. The most important viable tool that can help to boost an increase in productivity in leather products manufacturing is the Lean manufacturing tools.

Few industries utilise these lean tools in our country which can be proved as a real true beneficial factor resulted foreseen. Hence, in order to evaluate present Process Cycle Efficiency (PCE) Lead time and productivity implementation of Lean Principles in the leather products manufacturing prior to developing an improved strategy to bring the improved PCE, productivity and to reduce the lead time. These Lean tools apply in manufacturing at the production line for bi-fold wallets and after the implementation of of these Lean tools, productivity & Process Cycle Efficiency (PCE) was found very low % at the beginning and after the implementation of Lean tools it reached high % with lead time also be reduced; evaluated by takt time, bottleneck analysis, Cause Effect Analysis and Pareto analysis. The production flow was optimized by minimizing several Non-Value-Added (NVA) activities such as bottleneck, machine breakdown, queue time, waiting time, material handling time, etc.,

Nowadays higher productivity achievement is a very important factor for the manufacturing field, with the higher productivity; other various factors must be taken into consideration in manufacturing such as global competition, lead time and customer requirements in terms of quality with quantity. Continuous improvement with or without capital investment necessitates competitive manufacturing. Lean manufacturing is based on the “Toyota Production System – TPS” developed by Toyota which focuses on eliminating waste, reducing inventory, improving production and encouraging workforce to bring attention to problems and suggest improvements to fix upon.

Lean manufacturing has been increasingly applied by leading manufacturing companies throughout globally. Lean manufacturing core important vital concept is pulling production in which the flow process on the production shop floor is driven by demand from downstream pulling production upstream. Lean manufacturing facility is capable of producing the product in only the sum of its value-added work content time. Lean manufacturing main important scope is to eliminate waste and reduce the cycle time to increase the profit and competitiveness by increasing the production and decreasing the cost of product. In order to sustain the positive growth, it is essential to ensure the proper utilization of available all resources. The entire manufacturing sector requires the financial growth largely depending on minimizing excess work and in achieving productivity improvement.

This analysis of review was masterful with some specific objectives which were to identify, quantify and to reduce the Non-Value-Added (NVD) activities and time towards the exalted Process Cycle Efficiency (PCE) and therefore to reduce the lead time.                

– By Sundaramurthy Velmurugan, Leather Professional Consultant. Whatsapp: +918973231705