Browse Topic: Lean manufacturing

Items (105)
Weld Fatigue Assessment of Rail Track Maintenance Machinery: Regulatory Compliance and Practical InsightsSAE-PP-087469/29/2023
The use of appropriate loads and regulations is of great importance in weld fatigue assessment of rail on-track maintenance equipment and similar vehicles for optimized design. The regulations and available loads however are often generalized for several categories which proves to be overly conservative for some specific categories of machines. The work presented in this paper is about the strength and weld fatigue assessment of self-propelled rail on-track maintenance machines or similar equipment. It outlines the methodology and challenges associated with utilizing existing regulatory loads for weld fatigue assessment, specifically employing the endurance limit approach, also known as the infinite life approach. In cases where an endurance limit is undefined, particularly for welds, the fatigue strength limit at expected life cycles can be employed within the endurance limit approach. Availability of track-induced fatigue load data for the cumulative damage approach in track maintenance machines is often limited. Consequently, the Finite Element Analysis (FEA) based validation of rail TME often resorts to the infinite life approach rather than cumulative damage approach for track induced travel loads, resulting in overly conservative designs.\n\nThis work compares the EN (European Norm) and AAR (Association of American Railroads) approaches in using specified loads in FEA-based weld fatigue assessment concerning track-induced vertical fatigue loads. It explains how the choice of available regulatory load affects the fatigue life predictions in self-propelled TME, highlighting the necessity for the regulatory loads that closely represent the endurance limit approach or loads suitable for the cumulative damage approach in the context of rail track maintenance machines. The EN and AAR regulations play a pivotal role in determining the applicable loads and acceptance criteria within this study. Additionally, the BS7608 regulation is used to determine weld class and predict weld fatigue damage. The study employs both nominal and Hot-Spot stress approaches to investigate and calculate fatigue damage.
Dongari, Madhukar
SAE J4000 is a tool to identify and measure best practice in the implementation of lean operation in a manufacturing organization. Implementation of lean operation is defined as the process of eliminating waste exhibited in an organization’s value stream. Best practice in this process is Level 3 conduct as described in the standard’s component statements. A description of the levels of implementation is: A procedure for evaluation and scoring of each component will be included in the SAE J4001 Implementation of Lean Operation User Manual.
Automotive Quality and Process Improvement Committee
A Phased Approach to Optimized Robotic Assembly for the 777X2019-01-13753/19/2019
Low rate initial production of the 777X flight control surfaces and wing edges has been underway at the Boeing St. Louis site since early 2017. Drilling, inspection, and temporary fastening tasks are performed by automated multi-function robotic systems supplied by Electroimpact. On the heels of the successful implementation of the initial four (4) systems, Phases II and III are underway to meet increasing production demands with three (3) and four (4) new cells coming online, respectively. Assemblies are dedicated to particular cells for higher-rate production, while all systems are designed for commonality offering strategic backup capability. Safe operation and equipment density are optimized through the use of electronic safeguards. New time-saving process capabilities allow for one-up drilling, hole inspection, fastening, fastener inspection, and stem shaving. Multi-function end effectors with dual spindles permits drilling and reaming within a single clamp, and hybrid cutting fluid delivery enables a no-compromise approach to process optimization. New automated health checks and calibrations limit the need for operators and maintenance personnel to access the equipment. The integration of these innovative technologies provides a high level of process control while the timely deployment of additional phases maintains a lean production system.
Mir, RyanDeVlieg, Russell
Improving Manufacturing Efficiencies through Industry 4.0 Technologies in Aerospace2018-01-192910/30/2018
1 In the age of 4th industrial revolution, operational and information technologies are increasingly getting converged to help organizations improve their topline through new innovative products and services, and improve bottom line by improving efficiencies. This transformation is driven by convergence of many advanced technologies such as advanced sensor and communication technologies, big data, advanced analytics, Artificial Intelligence (AI), robotics, additive manufacturing, virtual and augmented reality (VR/AR). Enterprises digitization journey continues to adopt advanced technologies through multi-pronged approach to achieve their near-term and long-term goals. This paper summarizes Industry 4.0 journey, its relevance and applications to aerospace. It also summarizes how Industry 4.0 concepts can be applied to a composite manufacturing shop floor of aerospace components, how effective convergence of IoT, analytics, machine learning, AI and AR/VR help in improving the overall efficiency, reliability, availability and quality of the manufacturing shop floor by monitoring real time data to evaluate the overall performance of manufacturing plant “As Designed” Vs “As Operated” quantifying the business value.
Veluri, SastryKumar, RaviVasudevan, RamjiGorur, Ravi PrakashNampuraja, EnoseShankaraiah, MaheshTanjore, SimhaRao, Shama
Lean Product Development. How to Create Flow? Reflection after a 4 Years Implementation in One Business Unit - Part 12016-01-03464/5/2016
During the 4 last years, Lean has been successfully implemented in one of the Tenneco’s Business Units: Ride Performance. This paper reflects on the results and more specifically on the third principle of Lean [1] “How to make flow” and on the fifth principle “To strive for perfection” obtained in the fields of “Product Development” related to Processes, Tools and People. Processes and Hard Tools. How to improve the flow in the engineering processes? It will be shown that In general standardized processes supported by some integrated tools and, more specifically Some workload leveling in testing, CAD Departments, Standardization in design processes, testing procedures and prototypes development processes and Standardization and availability of components and parts for prototype building are key enablers to enhance flow in the Product Development. Additionally the application of some Poka Yoke principles improves the Product Development quality and front loading of the development process ensures the efficient realization of an optimized product solution. The hard tools are defined as tools supporting the processes and the people in their daily business. A couple of examples illustrate how the tools are bolstering the engineering flow. An example shows how to speed up some processes such as testing, the CAD design or the building of prototypes by sharing resources globally, i.e. efficiently making parts or components available from one engineering center to other locations. The integration of several local databases into one global standardized database helps the end user to both identify the location where resources are available and use it. Another example illustrates the process and the tools to analyze and benchmark the competitor products and technology trends. This tool employs standardized test procedures and report templates. People. To increase the competences of the Product Development group the skills are properly identified and reviewed on a regular basis by the manager. Coaching, Mentoring, Knowledge Sharing and Lessons Learned are supported by the function leaders whose roles and responsibilities include continuously improving the standards of their specialty and sharing of it within the organization. The Change Agents, who propagate the continuous improvement spirit, work closely with the functional leaders to help to identify opportunities for improving and supporting the execution of work by using structured problem solving methods. Soft Tools. The Soft tools [2] are defined as tools supporting Communication to drive alignment and commitment including the use of Visual Management. Problem Solving technics including PDCA and Continuous Improvement. Knowledge collection, Lessons Learned and Sharing Visual Management is a powerful tool to share information, to create transparency, to align and finally gain clear commitment of the stakeholders. Some examples as Obeya room and Cockpit will be presented. PDCA and problem solving are disciplined methods to identify, define, solve problems, driving a systematic behavior and thinking to continuously improve the current business. Lessons learned and Knowledge Sharing processes are supported by some tools to select, approve and finally share the information to the right audience. An efficient way to capture the lessons learned and the experience is to integrate design guidelines, generic DFMEA,DVP, BOM and Drawings into a tool which provides guidance and support the product design process. This tool is particularly efficient knowledge transfer method when bringing new engineers on board.
Garcia, PatrickRadous, JiriKrol, ArturBosek, JacekBaeten, Caroline
Value Streaming Through Customer Participation in Product Realization2016-01-03444/5/2016
Success in lean product realization depends on the ability to specify value from the voice of the customer at the beginning of the process. Value streaming, is therefore essential for assuring that the specified value is being pursued and achieved throughout the process. During lean implementation, however, it is usually assumed that nothing but value will be streamed if wastes are eliminated using value stream mapping. While waste elimination is necessary to make the process leaner and facilitate value streaming it is not sufficient for assuring that specified value is being streamed without structured and formalized participation of customers. With current structure of product realization processes, the voice of the customer is provided during the planning phase at the beginning of the process and customer satisfaction feedback is provided after product launch. With limited customer Participation during the process it is harder to assure that the voice of the customer specified value is being streamed. Shifting the process paradigm from planning, design, and manufacturing to the natural phases of inception, conception, and maturation would allow more structured and formalized participation of customers. Providing these necessary customers’ participations when needed would assure that specified value is pursued, streamed and ultimately achieved. In this paper an approach for assuring that the voice of the customer specified value is being streamed during traditional and lean product realization processes is discussed. For traditional product realization processes, value streaming and customer satisfaction could be greatly improved by structuring and formalizing customers’ evaluations of concept vehicles. For the lean product realization processes, value inputs start at the inception phase and value streaming continues through the product conception and development/validation. Participation of the customers is structured during formalized milestones to assure achievement of customers’ specified value.
El-Sayed, Mohamed
Implementing the Hybrid Lean-Agile Manufacturing System Strategically in Automotive Sector2015-01-90835/1/2015
In order to strike a balance between cost and availability, the present study presents the strategic implementation of the hybrid lean-agile manufacturing system. The proposed implementation is based on literature review and statistical analysis. The study presents short term and long term proposed plans for implementing this newly developed system in a sustainable way. It shows how the strategic facet of the hybrid lean-agile manufacturing system addresses the key manufacturing competitive dimensions. The paper presents as well a cost-benefit analysis in comparison with the lean manufacturing system and agile manufacturing system based on the net present value. The study shows that the expectedly most efficient among the manufacturing systems is the Hybrid Lean-Agile Manufacturing System with normalized comparative improvement of about 58% and 42%, respectively. The study concludes through a statistical sample that about one third of the variation in successfully dealing with the sources of competitive advantage in automotive sector can be explained by adopting the strategic facet of the hybrid lean-agile manufacturing system. The study is limited to the automotive manufacturing sector. The paper would be of interest to the seekers for efficient manufacturing systems such as lean manufacturing practitioners and agile manufacturing practitioners.
Elmoselhy, Salah A.
Implementation of BorgWarner Production System - Case Study at DivgiWarner Private Limited2012-01-20559/24/2012
In the pursuit of manufacturing excellence BorgWarner, Inc., USA has utilized some key aspects of Toyota Production System and General Motors Quality System Basics tools to create a systematic framework called as Borg Warner Production System (BWPS). The goal of BWPS is to have robust manufacturing systems to deliver flawless quality products at lowest possible cost and give hassle free customer experience. This case study covers the BorgWarner Production System implementation experience of DivgiWarner Pvt. Ltd. India, one of the BorgWarner's plant based in Pune and Sirsi, India. The BWPS consists of 7 foundational elements and 23 tactical strategies. These seven foundational elements are Safety and Environment, Quality Systems, Employee Development, Continuous Improvement, Lean Manufacturing, Pre-Production Planning, Metrics and Audits This framework delivered following benefits to the company: “Zero” safety incidences Customer PPM reduced from 675 to 122 100% On Time Delivery to customers Continual improvement - more than 300 kaizen projects implemented every year Overall Equipment Effectiveness increased from 41% to 82.9% Inventory Turn Over Ratio (ITOR) increased from 4.8 to 10.1 Material movement in the plant reduced by 68% This paper uses BWPS as an example to illustrate how to implement similar production systems, in order to improve manufacturing effectiveness. We also show how to set performance base lines, track continuous improvements, and communicate progress to pursue perfection.
Vani, Dipak AnnasahebDeshpande, Sudhindra
Legacy 500 Empennage Assembly - Design for Manufacturing2012-01-18729/10/2012
On product design the use of composite materials has been steadily growing on aircraft industry, driven primarily by weight lost on structural components, which leads to better efficiency on fuel consumption, closely linked to economic issues and sustainability. On manufacturing planning the use of lean concepts has helped aircraft manufacturers to better manage its production resources leading also to more efficient and sustainable ways to fabricate and assemble aircraft structures. This paper describes how Embraer is combining these two philosophies for the development of the vertical and horizontal stabilizers of its latest product, the Legacy 500, and the planning and construction of its new composites assembly line in Evora. It first analyzes how automated composites fabrication methods like ATL help to reduce parts thus reducing weight and assembly hours. It also analyzes solutions developed to guarantee design for assembly and design for automation concepts. Going from product design to manufacturing planning the assembly line is based on a flexible, modular monorail system. This system allows to assembly both stabilizers on the determined rates and is due to its flexibility capable to absorb rate changes and can be also be converted for new products. Robot automation is used for panel drilling and fastening. Handling systems assist the workers in manipulating huge and heavy parts to and from the line. All these applications result on high quality products and very efficient production methods which ultimately generate a more sustainable way to manufacture aircraft components.
da Silva, Daniel CarlosGuimaraes, GustavoDa Rocha Lima, AntonioZenebon, Fabio SilvaCarvalho, Andre BarbosadearaujoMeffert, Gerhard
Automated Horizontal Tail Plane Assembly Environment2012-01-18919/10/2012
Cost reduction efforts are driving aircraft manufactures to new assembly methods and strategic sourcing approaches. Global challenges, international competitors as well as increasing wages and salaries are leading to higher automation levels. ThyssenKrupp started researching new harmonized solutions for wing box, center wing box, vertical tail plane and horizontal tail plane that in 2007. The first step was to research the available technologies and to define how they can be used together to attend the new requirements of the aircraft industry. In 2009 ThyssenKrupp got the opportunity to apply the achieved results in a real application. One of the major challenges was to decide on the main premises for the assembly concept. Business case studies showed reasonable automation approaches; early investigations for health and safety topics showed up potential issues and detailed 3D concepts gave reliable results during the preliminary design review. The outcome is an automated environment for HTP joining and outfitting activities. The HTP joining area mainly consists of servo-controlled positioning systems with laser-tracker metrology systems and automated drilling machines (column-type). The pulse line mainly consists of servo-controlled assembly stations as well as ergonomic platform systems. The result is a state-of-the-art assembly environment, managed by ThyssenKrupp System Engineering and in cooperation with suppliers.
Brooksiek, MichaelBunke, Joerg
Equivalence Unit Assumptions on Productivity and Capacity Evaluations2012-01-05024/16/2012
In addition to providing a wide product range and meeting individual requirements of the customers to make the companies able to orient themselves to the competitive conditions in the automotive industry, properly structuring a capacity-productivity calculation algorithm is of a great importance in obtaining a competitive price advantage. In cases product diversity is too wide, and finished products cannot be measured with a single unit, measuring the production efficiency gets complicated. In addition, the ability to analyze all the inputs and outputs of the production with a single unit based on the same value for enterprises instead of analysis of combined units carried out based on a single perspective when calculating the production efficiency of the enterprises underlies continuous improvement and being able to set goals for the processes. This study describes an integrated system design based on equivalence logic, which can set forth production efficiency and the capacity utilization level in many aspects. First, equivalence situation of the finished products compared to one another was evaluated based on parameters such as the machine time, the labor time and energy utilization, and efficiency criteria have been developed according to the equivalent product regarding these parameters. Efficiency and activity criteria, and globally-accepted metrics (for example, from OEE) have been utilized in the study. Furthermore, the metrics that have been developed concerning measurement of the labor productivity, and could not be explained bu OEE are remarkable The enterprises that can express their outputs in multiple units, and use only one of these units in productivity measurement will measure more accurately their productivity and capacity for their enterprises, and set their targets more realistically by applying the model created in the reference study.
Karaca, TahsinSoner, MurathanErtunc, SinanArpacik, Mehmet AliKaraagac, MustafaKanbolat, Ahmet
Critical Success Factors of Lean Manufacturing Implementation in Automotive Industry in China2012-01-05164/16/2012
Purpose - This research aimed to investigate the process of lean manufacturing implementation in automotive industry in China in order to identify the critical success factors. Design/methodology/approach - A review of relevant literature is used to identify potential critical success factors for lean manufacturing implementations. The research had targeted lean-manufacturing management, practitioners, process users, and consultants working in automotive industry in China. Data were collected with an electronic survey which included 20 close ended questions, each measured by using five-point scale, Out of total 200 questionnaire distributed, 80 useable responses were received resulting in 40 % response rate. A judgmental sampling technique had been selected. Both descriptive and inferential statistics had been used to analyze this data. Findings - Our findings indicated that the belief among the respondents that management engagement, communication, training, monitoring progress among others are critical success factors for lean manufacturing implementation in automotive industry in China. Also, the findings of the survey confirm that there is no significant difference among different experience levels, functions, and automotive sectors in perceiving and evaluating the critical success factors of lean manufacturing implementation in automotive industry in China. Research limitations - The sample was limited to automotive industry in China and the results cannot be generalized too widely. However, this can be overcome by conducting other studies in different countries or industries. Practical implications - Management and consultants working in automotive industry in China should focus on management commitment, communication, monitoring progress, and training to ensure successful implementation. Originality/value - This research identified the critical success factors lean manufacturing implementation in automotive industry in China.
El Safty, Shady Baher
Fixturing and Tooling for Wing Assembly with Reconfigurable Datum System Pickup2011-01-255610/18/2011
The aerospace manufacturing sector is continuously seeking automation due to increased demand for the next generation single-isle aircraft. In order to reduce weight and fuel consumption aircraft manufacturers have increasingly started to use more composites as part of the structure. The manufacture and assembly of composites poses different constraints and challenges compared to the more traditional aircraft build consisting of metal components. In order to overcome these problems and to achieve the desired production rate existing manufacturing technologies have to be improved. New technologies and build concepts have to be developed in order to achieve the rate and ramp up of production and cost saving. This paper investigates how to achieve the rib hole key characteristic (KC) in a composite wing box assembly process. When the rib hole KC is out of tolerances, possibly, the KC can be achieved by imposing it by means of adjustable tooling and fixturing elements. A test rig has been designed and built that is used to experimentally investigate the capability of both the tooling and fixturing concepts. Some experiments have been carried out that successfully demonstrate the capability of the reconfigurable fixturing technology to achieve the rib hole KC.
Bakker, Otto JanJayaweera, NiroshMartin, OliverTurnock, AndrewHelgosson, PeterSmith, TonyPopov, AtanasRatchev, SvetanTomlinson, DavidWright, JonSummers, Mark
Innovative Robust Solutions for Lean Manufacturing in Automotive Assembly Processes2011-01-12544/12/2011
The article presents an innovative approach to the implementation of a robust design optimization solution in an automobiles assembly process. The approach of the entire project is specific to the 6 Sigma optimization process, by applying the DMAIC cycle integrated in a robust engineering approach for rendering lean the final product assembly process. According to the improvement cycle, the aspects specific for such a process are presented sequentially starting with the “Define” phase for presenting the encountered problem and continuing with the presentation of the scope of the project and its objectives. The “Improvement” cycle phase is applied by the analysis of the monitored 6 Sigma metrics (defined during the previous “Measure” phase and the cause and effect analysis, done during a brainstorming meeting developed during the “Analyze” phase). There follows a proposal for the innovative robust solution by which the assembly process is optimized. Therefore, we propose the final assembly of already painted doors on the already assembled cars with a special work-holding which is easy to handle by the human operator. The automation of designed and implemented solutions provides features of error proofing for the assembly process in the case in which the doors are not located accordingly on the work-holding locating elements, which may lead to various inconveniences during the assembly on the vehicle and/or some faults of the door quality, such as scratches or deformations because of the impacts. The initially presented process indices, for the not yet optimized process are finally evaluated after the implementation of the innovative solution for a comparative study of the initial monitoring results and after the implementation of the proposed corrective solution. This underlines the critical conclusions that are induced during the “Control” phase. The final conclusions point to the corrective / preventive actions for a sustainable and reliable optimization, which give the maximal process its overall efficiency.
Negrus, Andrei MihaiMihail, Laurentiu AurelChiru, Anghel
Quality Improvement Directly on the Production Floor2010-36-046610/6/2010
Over the past year, commercial vehicle manufacturers have already taken numerous measures to adapt to the economic turmoil, by laying off of temporary workers, reducing shifts and cutting back working hours among other steps. Soon, further-reaching measures may have to be taken to adjust to lower output levels. "The commercial vehicle industry is facing the prospect of having to make fundamental changes to its operations," according ACEA - European Automobile Manufacturers' Association (2009). Because of these facts the automobile world is each day more interested in Toyota industry development, while European and American automobile industry are in decadence, Toyota had accumulated profits every year during ten years until 2007. The Toyota wastes reducing methods, productivity and quality finished imposing his production administration system to the worldwide automobile industries. One big difference between occidental thinks' and Toyota production system, is that they works strongly inside people management, teaching the employees to solve small problems, avoiding in this way the big ones, increasing the final product quality. In this paper, will be presented a real case of quality improvement applied directly on production floor in an automobile Brazilian industry. The studied company manufactured this specific vehicle model in Brazil to be exported to Europe.
Baraldi, Emilio C.
Implementation of Lean Manufacturing to Improve Competitiveness2010-01-202510/5/2010
In traditional manufacturing processes a lot of material is wasted in hidden ways. These can be identified through Lean Manufacturing systems. It is proven that the Lean Approach eliminates waste and improves value. This reduces excessive investment in working capital and improves Return on Invested Capital (RoIC). As a result, the shareholder's value is maximized through simultaneously reducing costs and increasing capital efficiency. To demonstrate this we analyzed the production process of the Upper Output Shaft , a key component in a typical drive train assembly like a Four Wheel Drive transfer case, used in a pickup truck or SUV. Value Stream Mapping (VSM) is used to identify and reduce non value-added activities. VSM methodology for Output Shaft delivered the following benefits for DivgiWarner: Reduction in Inventory by 66%, Process cycle efficiency improved by 228%, Manpower cost reduced by 43% Material movement in the plant reduced by 68% Improvement in RoIC by 32% Cost of part reduced by 11% This paper illustrates how to implement lean principles in the manufacturing environments of order-based medium scale production to eliminate wastes in the form of defects, unnecessary processing, and excess inventory. With the use of lean tools, we also show how to set performance baselines, track continuous improvements, and communicate progress to pursue perfection
Pingale, AbhijeetVani, Deepak
Virtual Commissioning of Factory Floor Automation: The New Paradigm in Vehicle Manufacturing2010-01-00134/12/2010
Never in the history of the automotive industry has it been more critical for automakers to prove that they are capable of producing vehicles efficiently and cost-effectively. In the coming months and years there will be a growing requirement for lean product design and manufacturing strategies that will re-shape the way the automotive suppliers and OEMs conduct business. Computer-aided-design and manufacturing have become commonplace in automotive product design and manufacturing processes. These technologies enable efficiencies and quality improvements through virtual simulation and testing of kinematic designs. However, to date, there has been no ability to incorporate the process controls into these simulations. Vehicle introductions require new manufacturing processes and equipment which is typically outsourced by the OEMs to a supplier. Equipment, such as large welding and assembly lines, are built and tested at the supplier facility then disassembled, shipped, reassembled, and retested on the OEM floor. This process is cumbersome, expensive and increases the total time required to complete a project. This paper will describe a paradigm shift taking place in the development of automotive assembly systems. Using a new technology that enables engineers to build a replica of production equipment and processes in an interactive 3D virtual environment - complete with mechanical, electric, hydraulic and pneumatic systems- the manufacturing process can be commissioned weeks or months before launch and with higher quality
David, Kenneth
AN OPTIMAL SOLUTION THROUGH LEAN MANUFACTURING USING VALUE STREAM MAPPING TOWARDS EFFICIENT PRODUCTION FOR A WORLD- CLASS AUTOMOBILE BRAKES MANUFACTURING COMPANY2009-28-005412/13/2009
Today, numerous companies have a major opportunity to reduce their costs and customer lead time and cycle time through the application of Lean Manufacturing processes. In recent years, almost every manufacturing industry has been trying to get ‘lean’. Lean thinking represents a set of principles and techniques for the identification and elimination of wastages in manufacturing and administrative processes. Value Stream Mapping (VSM) which is one of the lean manufacturing approaches has emerged as the preferred way to support and implement the lean approach. VSM is a helpful tool to identify the waste and improvement areas. VSM enables a company to see the entire process in both its current and desired future state, and develop the road map that prioritises the projects or tasks to bridge the gap between the current state and the future (lean) state. Improvements in processes, facility layouts, and managerial spans of control encourage redefining an organizations hierarchy and adopting a value stream management system. In this work, the Information flow, Current state, Value added time and Non-value added time across a leading automobile brakes manufacturing company and its Subcontractors have been studied to achieve value stream management or lean organizational structures. A future state has been proposed in which the reduction of raw material inventory, WIP inventory, finished goods inventory and Lead Time. This paper describes the value stream analysis from current state mapping to future state mapping including the lean concepts, metrics and methods that provide improvement. Eventually the current state and future state have been compared to propose an optimal manufacturing system.
Satheeshkumar, V.Renald, C.J.ThomasThiagarajan, M.Sathiyamanoj, G.K.
Lean Product Development - Redefining the Indian Automotive Product Development Process using Lean Framework2009-01-01174/20/2009
“Building quality into processes” - Eiji Toyoda, Toyota Motor Corporation The Indian automotive industry has grown at a Compound Annual Growth Rate (CAGR) of 14 per cent per annum over the last five years. According to the UNIDO International Yearbook of Industrial Statistics 2008, India features among the top 15 auto-makers. Currently, it ranks 11th in the world in terms of car production and 13th in terms of commercial vehicle production. As India is becoming a hub for global car makers, companies are looking to enhance their component engineering, product design and development capabilities in India to increase their share in the automotive knowledge-based business. So there is an urgent need to infuse new process improvement techniques to the product development cycle, to stay ahead of the global competition. This paper discusses about the basics of lean principles & wastes, lean product development and mainly discusses about the fundamental framework for applying lean to the product development process for Indian automotive industries. The following building blocks are discussed through lean framework: 1. Lean R&D Structure 2. Lean Implementation 3. Lean Rollout 4. Lean Tools & Techniques applied to PD 5. Lean Enterprise Model 6. Implementation Challenges We have also given a case study about comparing the seven manufacturing wastes with the product development wastes (Design stage - CAD Modeling and drafting) that mainly occurs in the PD process of Indian automotive companies.
Anand, D . UmaJanakiraman, S. R.Sethukannan, V. S.
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