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    LEAN Manufacturing Case Studies

    Uploaded by

    Kartik Singh
    The document describes the implementation of lean manufacturing practices at Siemens' Kalwa plant in India. It discusses how the plant transitioned from a batch processing model to one based on lean principles like just-in-time production and kanban systems. This reduced inefficiencies like unnecessary motion, high inventory levels, and errors. Benefits of lean implementation included reduced costs, improved space utilization, increased productivity and profits.

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    © All Rights Reserved

    LEAN Manufacturing Case Studies

    Uploaded by

    Kartik Singh
    152 views12 pages
    The document describes the implementation of lean manufacturing practices at Siemens' Kalwa plant in India. It discusses how the plant transitioned from a batch processing model to one based on lean principles like just-in-time production and kanban systems. This reduced inefficiencies like unnecessary motion, high inventory levels, and errors. Benefits of lean implementation included reduced costs, improved space utilization, increased productivity and profits.

    Original Description:

    Lean case study of Siemens and Harley Davidson on how they implemented lean

    Original Title

    LEAN Manufacturing case studies

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    The document describes the implementation of lean manufacturing practices at Siemens' Kalwa plant in India. It discusses how the plant transitioned from a batch processing model to one based on lean principles like just-in-time production and kanban systems. This reduced inefficiencies like unnecessary motion, high inventory levels, and errors. Benefits of lean implementation included reduced costs, improved space utilization, increased productivity and profits.

    Copyright:

    © All Rights Reserved
    152 views12 pages

    LEAN Manufacturing Case Studies

    Uploaded by

    Kartik Singh
    The document describes the implementation of lean manufacturing practices at Siemens' Kalwa plant in India. It discusses how the plant transitioned from a batch processing model to one based on lean principles like just-in-time production and kanban systems. This reduced inefficiencies like unnecessary motion, high inventory levels, and errors. Benefits of lean implementation included reduced costs, improved space utilization, increased productivity and profits.

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    © All Rights Reserved
    You are on page 1of 12

    ANIRBAN SIKDER

    KARIK SINGH
    RASIKA IYER

    First workshop, 1955

    Started with 10 employees

    Major divisions: Industry, Energy, Healthcare and


    Consumer products

    Kalwa Works: Medium Voltage division, sole


    manufacturer

    Switchboard: second largest MV factory outside

    Germany

    Batch Processing dampened


    inefficiencies

    High frequency of errors

    Increased amount of scrap

    Increased customer orders

    Low labor productivity, high


    inventory levels

    Old layout

    Result: Reduced unnecessary motion

    New layout

    OLD

    NEW

    14 VI Housing
    stored in one pallet

    36 VI Housing in one
    trolley

    Separate storage
    location for pallet
    trucks

    No separate storage
    required for pallet
    trucks

    High material
    movement

    Material movement
    reduced considerably

    Movement of kanban
    card from table drawer
    to kanban board

    Feeding of material
    against kanban card

    Result: Reducing waiting time,


    Inventory control

    Kanban system for


    cageboxes

    JIT was to focus upon ( parts available at


    the right time and quality)

    No batch supplying

    Long term plans were created to


    implement Lean principle at the vendor
    side whereas, short term plans to
    implement pull philosophy of lean system

    Reduced storage and inventory space in


    the factory

    Dashboard introduced , issues to be


    highlighted in the board following concerned
    personal

    Display daily out of each assembly lines to


    show production progress

    Training and workshops organized to narrow


    down the skill gaps

    Joint prayer and exercise sessions for each assembly line at the
    beginning of every shift.
    Instill a sense of Team Belongingness

    All the members were given a T-shirt imprinted with Lean logo
    as a uniform
    sends message of team Effort

    Regular interaction between top management and staff

    Reduction in inventory levels and


    associated costs

    Improved space utilization

    Increased productivity of labor

    These Benefits resulted in

    Higher throughput

    Increased profits for the factory

    http://www.wseas.us/elibrary/conferences/2010/Constantza/MEQAPS/MEQAPS-19.pdf
    http://people.tamu.edu/~anand_vijaykumar/index_files/INTRODUC.
    pdf
    https://www.scribd.com/doc/169286588/Lean-Implementation-atSiemen-s-Kalwa-Plant-pptx
    https://cb.hbsp.harvard.edu/cbmp/product/W12998-PDF-ENG

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