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Traditionally operated manufacturing industries are facing problems like low productivity, longer production lead time, high rework and rejection, poor line balancing, low flexibility of style changeover etc. These problems were addressed in this study by the implementation of lean tools like 5S, continuous flow, quick change over, total productive maintenance. After implementation of lean tools, results observed were used to assess the leanness of the plant floor. The key benefit of assessment is to identify the current state of production plant. And also to track the overall performance of the plant and it is evident that the leanness level can be improved by focusing on the key areas. This study is conducted in the steering knuckle manufacturing section in a manufacturing company. It includes time studies and current value stream mapping. Lean assessment was carried out using questionnaire which helped in diagnosing the lean status.

Assessment of Lean Manufacturing in a Manufacturing Industry