IMPLEMENTATION OF LEAN PRINCIPLES IN INDIAN AUTOMOTIVE MANUFACTURING

IMPLEMENTATION OF LEAN PRINCIPLES IN

AUTOMOTIVE MANUFACTURING INDUSTRIES

USING DIFFERENT MODELS

AKSHITH – 1005-14-765329

Department of Mechanical Engineering

UNIDO–ACMA Model

United Nations Industrial Development Organization (UNIDO)

MOTO OF UNDIO

• Accelerate sustainable Industrial Development

• Poverty Reduction

• Environmental Sustainability

UNIDO–ACMA Model

Automotive component manufacturers association of India

(ACMA)

• The All India Automobile & Ancillary Industries Association

• (AIA & AIA) – 1959.

• It was renamed as ACMA – 1982.

• It has more than 650 member companies in india.

• It contribute more than 85 % of the total auto component

production.

UNIDO–ACMA Model

• UNIDO in collaboration with the Government of India and

ACMA launched the UNIDO–ACMA partnership programme

for the Indian auto component industry in November 1998.

Purpose : To help Indian auto component manufacturers to

alleviate the effects of the abovementioned challenges.

Employee involvement - Total employee involvement (TEI)

Introduces :

• Intensive classroom as well as practical training

• Small Group Activity

• Quality Circle

• Suggestion Schemes and safety

5S- workplace managementWorkplace organization (5S) and waste elimination (3 M) are combined.

• Sort Muda

• Set in Order Muri

• Shine Mura

• Standardize

• Sustain

Quality Management : Poka Yoke Achieving excellent quality with minimum utilization of resources and cost.

Inventory managementCost-effective inventory management is possible through application of use of red tags, quick change over, i.e., single-minute exchange of dies (SMED), small batch size, single-piece flow and containerization.

Productivity improvementEstablishment and sustenance of productive work culture are the building block of productivity improvement with ‘‘Low cost practice’’.

SustenanceThis can be achieved through process of sustenance of Lean practices. The desirable results are stability in process, continuous improvement and customer satisfaction by aligning with cluster activities.

ISM MODEL - Interpretive Structural Modeling

Human resource management practice bundle

To identify the role human behavior plays in the performance of operating systems.

Employees must be aware, motivated and trained systematically to make a smooth transition to Lean culture.

Creativity and innovation practice bundle

• continually challenges - creatively

• Talent

• Skills

• Identifying waste and to remove it.

Health and safety practice bundle

Organizations must promote a healthy working environment should suit employee’s different physical and psychological requirements and capacity.

Waste elimination practice bundle

• non-value added activity

• facilitating cost reduction - eliminated or simplified.

• Consumers are not willing to pay for waste.

Conformance quality practice bundle

quality excellence through –

• total quality management (TQM)

• total quality control (TQC)

• statistical quality control (SQC)

• statistical process control (SPC)

• Six Sigma

Volume flexibility practice bundle

• To cope with changes in the nature, mix, volume or timing of its activities.

• If the production changes to meet a peak demand - still work efficiently during slacker times.

Delivery reliability practice bundle

• Improved flow of material and information throughout the supply chain.

Low-cost practice bundle

• Profit can be increased by reducing cost price of product.

• profit earned is equal to the difference of market price and cost price of product.

Sustenance and perfection

‘‘Sustainability is not a method or a tool, it is the state of a company in which the efficiency of resources is maximized, customers are satisfied to a great extent, an improved condition is long-lasting, success is maintained and competitive advantage is sustained’’

LEMIS - Lean Environmental Management Integrated System.

PRACTICAL IMPLEMENTAION OF EMS

Reduction in land consumption

In the construction of new manufacturing sites, preference isto be given to sites that have already been used industrially orto industrial wasteland sites respectively.

.

Prohibition of the use of substances particularly harmful to health

Prohibition of asbestosPolychlorinated biphenyls (PCBs)chlorinated hydrocarbons (CHCs) fluorinated chlorinated hydrocarbons (CFCs)Sulphur hexafluoride (SF6)

Instead they implemented

100% environmentally-friendly production and disposal

Processes in the press shop

• The use of compressed air is to be avoided as far as possible.

• Biodegradable hydraulic oils are be used wherever possible or

economically reasonable.

• Refrigeration should be implemented by way of combined power / heat

/cold generation.

• Monitoring of leak tightness.

Assembly processes

Implemented during the filling of vehicles with fuels and lubricants,

the storage of hazardous substances (storeroom, filling facility) and

also in conjunction with hydraulic plants and systems.

Processes in mechanical manufacturing

• Special protective mechanisms are to be used to protect

the employees in the production process

• The comprehensive introduction of processes using small

amounts of emulsion or working free of cooling lubricants

will make a significant contribution towards meeting these

targets as well as near net shape manufacturing.

Result & Conclusion

• Compare the UNIDO–ACMA Model & ISM Model and finding ISM model is more advance.

• Through the LEMIS model helps to specify these performance measures making the standard achieve sustainability and continual improvement.

• Understanding the ISO 14001 standard requirements

Reference

J. R. Jadhav • S. S. Mantha • S. B. Rane (2014)Roadmap for Lean implementation in Indian automotive component manufacturing industry: comparative study of UNIDO Model and ISM Model.

Perumal Puvanasvaran, Robert Kerk Swee Tian, Suresh A/L Vasu (2014)Lean Environmental Management Integration System for Sustainability of ISO 14001:2004 standard implementation.

Sustainability Report of Volkswagen. Available at www.volkswaganeg.com

Naveen Kumar, Sanjay Kumar, Abid Haleem, Pardeep Gahlot (2013) Implementing Lean Manufacturing System: ISM Approach.

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