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The objective of the Lean Manufacturing Project is to reduce waste, improve process efficiency, shorten production cycles, and enhance product quality by applying lean principles throughout the production floor. With market competition intensifying, we needed a streamlined approach that removes inefficiencies, empowers employees, and ensures every activity adds value. Lean Manufacturing provided a proven framework for sustainable transformation.
Our first step was a comprehensive lean audit and value stream mapping (VSM) of the entire manufacturing process: Mapped current-state workflows Identified 7 wastes (Muda): Overproduction, Waiting, Transport, Overprocessing, Inventory, Motion, Defects Highlighted process bottlenecks and non-value-adding steps The VSM revealed long idle times between shifts, excessive movement of materials, and redundant quality checks. These insights guided our lean implementation roadmap.
We applied Lean principles to eliminate non-value-adding steps. Key actions included: 5S System Implementation (Sort, Set in order, Shine, Standardize, Sustain) Kaizen Events for continuous improvement Setup Time Reduction through SMED (Single Minute Exchange of Dies) By reorganizing workspaces and reducing time lost during machine setup and changeovers, we achieved a 17% improvement in overall equipment efficiency (OEE). Kaizen events empowered our operators to suggest and implement small changes with big impacts.
We introduced partial automation in material handling and real-time monitoring tools: Automated Guided Vehicles (AGVs) for internal logistics SCADA Systems for real-time production monitoring Sensor-Based Alerts for machine anomalies AGVs reduced human labor requirements and increased transport speed within the facility. SCADA helped in collecting live data from machines, improving decision-making and maintenance planning. Downtime notifications via sensors minimized unexpected halts.
Hear from our satisfied clients about our factory’s quality, reliability, and exceptional service standards.
