Implementing Lean Manufacturing in India : A Case Study

Abstract: Lean manufacturing tools and principles are commonly applied in many different types of organizations around the globe. However, it is not that common in less developed countries, particularly not in the smaller organizations. In this report, we present a case study where lean manufacturing principles have been applied in a small aluminium foundry in India in order to improve its production. Tools, methods and principles such as elimination of waste, value stream mapping, genchi genbutsu, 5S and implementation of improved product flow and takt time has been used to make changes in the process flow, factory layout, equipment and labour. After lean manufacturing was implemented and changes were made, the aluminium foundry managed to improve its production by approximately 100%.