Productivity improvement using different lean approaches in small and medium enterprises (SMEs)

Small and Medium Enterprises (SMEs) play a crucial role in the Indian economy. To remain competitive in the global market, application of Lean Manufacturing Techniques (LMT) helps SMEs to improve their processes in alignment with customer needs. The purpose of this study is to reduce overall lead time by identification and eliminating non-value added activities (NVA) from the manufacturing system. In this paper, the current manufacturing processes have been thoroughly studied using the principle of work study. Several lean approaches such as- TAKT time computation, Value stream Mapping (VSM), layout optimization, Kanban, Andon etc. have been used to make improvement in line efficiency and hence productivity. The study shows that use of line balancing technique, matches the cycle time with calculated TAKT time. And the efficiency of the line has increased approx 10% and hence balance delay got reduced. Again VSM helps to reduce the lead time of foundry shops by 51 minutes. It is one of the few studies that deal with productivity improvement in Indian SME.