Lean Concept Implementation Practices in Small and Medium Scale Pharmaceutical Industry- A Case Study

This paper describes an exploratory study of lean techniques and an extant of its implementation in a pharmaceutical industries. The main purpose of this paper is, at how much extant adoption of lean techniques and elimination of wastage and non-value added activities in a pharmaceutical industries. A questionnaire survey is prepared to know the extent of lean techniques implementation. Questionnaire survey send to the respondents of various department (production and planning, human resources, quality and control, transportation, inventory control etc.) of an organization and asked to rate the each of these areas. This study also inspect the drivers and barriers that affect the adoption of lean techniques. The mean value for each area is obtain after calculations on SPSS and statistical analyses were performed for each area. Further, this study also examined different subjects related with lean techniques adoption for example its comprehension among the respondent organization, its advantages and impediments, the techniques and tools used, etc. The outcomes from this study also revealed the hindrance that forestall or postpone the lean execution. The main obstacles in adoption of lean technology are the absence of understanding lean ideas and shop floor representative’s attitude. Keywords: lean manufacturing, lean barriers, SPSS, mean score, driving forces

LEAN MANUFACTURING vs COVID-19

During the COVID-19 pandemic, companies coped and still must deal with uncertainty greater than ever. Due to the unpredictability of consumer demand, the incredible growth in demand for certain products, dramatic fluctuations in supply chains, and general economic instability, the future still looks uncertain. It is up to the manufacturers to determine how things will be sorted out in the new normality, i.e., which changes will be long-lasting or even permanent. Lean production has emerged in recent decades as an excellent solution to increase the economy and quality of production and meet customer needs. In the market conditions affected by the COVID-19 pandemic, producers work in a significantly changed environment, and many wonder whether lean production remains as relevant and valuable as in the past. The paper discusses lean production from different aspects as the essence of the principles of the lean concept, events during the pandemic, and expectations in the post-Covid period. We used some examples to support the analysis of factors that negatively affect the course of lean production as well as some bright examples of companies that took advantage of lean production in the new conditions. The conclusions consider answer whether lean production will survive the consequences of the COVID-19 pandemic.

ENHANCEMENT OF PRODUCTION BY LEAN MANUFACTURING METHOD

The thesis proposes a method for introducing lean manufacturing using string diagram in an operating CNG high pressure storage tank manufacturing job shop at Jayfe Cylinder Ltd. Haryana. By applying lean manufacturing using process layout diagram to produce part families with similar manufacturing processes and stable demand, plants expect to reduce costs and lead-times and improve quality and delivery performance. The thesis outlines a method for assessing, designing, and implementing lean manufacturing using process layout diagram, and illustrates this process with an example. A manufacturing cell that produces high pressure steel tank container for commercial & automobile customers is implemented at cylinder tank Machining Centers. The conclusion of the thesis highlights the key lessons learned from this process.

Mediating Role of Green Supply Chain Management Between Lean Manufacturing Practices and Sustainable Performance

Manufacturing companies in today's industrial world are seeking to use the new manufacturing process methods. The primary goal of corporations is to achieve optimum production while deploying minimal capital. The fundamental purpose of this study is to examine the influence of various lean manufacturing practices on the sustainability performance of companies and the mediating role of green supply chain management (GSCM). The data was gathered using questionnaires from 250 Pakistani manufacturing firms and analyzed using AMOS 25. Results demonstrate that process and equipment, product design, supplier relationships, and customer relationships significantly affect sustainable performance. It is also recognized that Green Supply Chain Management mediates the interaction between HR processes, product design, supplier relationship, customer relationship, and environmental performance. The findings of this study will enable managers and decision-makers of manufacturing companies to increase sustainable efficiency and reduce waste through the use of lean manufacturing and GSCM implementation.

Lean Enhancement by Application of Total Interpretive Structural Modelling

Prioritizing of factors for effective lean manufacturing poses a challenge to management due to complexities in interrelationships. Diligent understanding of measures of lean manufacturing assumes great importance. Essential manufacturing flexibilities take care of uncertainties driven by dynamics of the market. Interrelationship between factors of manufacturing flexibility and lean manufacturing adds to complexity. Judicious analysis of these factors is imperative to understand their effect on lean manufacturing. Total interpretive structural modeling methodology is used for establishing relationships among the factors affecting lean performance. Case studies have been carried out and TISM is applied to understand the dynamism of factors. Study brings out how the organization of the companies and level of automation help in understating the driving and dependence power. The study helps in understanding the influence of hierarchy and level of factors identified by TISM technique on lean performance as also the factors which merit attention of top management to achieve better results

Teaching Circular Economy and Lean Management in a Learning Factory

Traditionally, industries followed a linear process of resources consumption: taking raw materials from nature, transforming them into products, and selling them to consumers (who discarded them when they were no longer useful). Nowadays, due to the sustainable development concerns, there is an increasing awareness on the society for reuse, repair, recycling, and remanufacturing to avoid resource depletion and achieve waste reduction. Following this idea, with the aim to train students and practitioners in lean manufacturing and circular economy concepts and tools, a learning process organized in three sequential phases was developed, starting with the manufacture of a toy car (25 kg and over 100 pieces) using a traditional push system, then reengineering the process to implement pull system and lean manufacturing concepts, and finally, considering a circular economy pull system through the reuse and recycling of parts and components. In this way, the importance of reducing waste in manufacturing and the reduction in the use of raw materials by considering the 3Rs is highlighted.

Industrial Case Study on Lean Manufacturing Implemented on Manufacturing Polypropylene Ropes Industry Amravati

Lean manufacturing has been one of the most standard method in the manufacturing and service industry for elimination of waste. Every manufacturing industry has to put in continuous effort for its survival in the current impulsive and competitive economy. The purpose of this paper is to investigate the adoption of lean manufacturing tools and techniques in the manufacturing industries. This paper is based on actual implementation of lean manufacturing techniques. It focuses on the execution of flow from the start until the end of the implementation, types of analysis and tools applied, evaluation methods and how the industry benefited from the implementation. In this case study we particularly focused on Shop floor management, Quality Management (QM), Supplier and Customer Management (SCM) and Workforce Management (WM). After going through various testing on implementation of Lean Manufacturing principles in Micro Small medium Enterprise (MSME), researcher studied thoughts of some author where they discussed pragmatic problems they overcome while implementing lean principles in developing economies MSME. At the end, the result shows that there is monthly increment in capital productivity and labour productivity. And decrement in inhouse rejection, breakdown hours and customer complaint from the implementation of lean.