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Operations Article | Implementing Lean Production Techniques in India

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Implementing Lean Production Techniques in India

- by Vaishnav Tadatmya Ashok *

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Company Main products Major lean practices adopted Benefits realized
Lucas-TVS Ltd. (Sethuraman & Tirupati 2000) Auto electrical products, fuel injection systems
  • Highly structured approach to factory relayout (Nagare cell formation)
  • One-piece flow
  • Quality task force approach: autonomation, kanban, poka-yoke, TPM, strategic pull
    		•  Over 13 years:
  • Lot sizes: from 4000 to 40
  • Rejection rate: from 10% to 2.5%
  • Scrap: from 3% to 1.5%
  • Downtime: from 2% to 0.2%
  • Space utilization: 333% increase
    		•
    Sona Koyo Steering Systems (Jagannathan 2004) Mechanical & power steering systems
  • Implementation of Toyota practices with help from TPS experts
  • Part of Maruti’s TQM cluster of suppliers
  • TQM tools (gap analysis, root cause analysis, etc.)
  • TPM
  • Winner of Deming Prize, 2003
  • Customer rejection rate: from 1579 PPM to 112 PPM
  • Plant rejections: from 17300 PPM to 876 PPM
  • Delivery against schedule: from 92% to 99%
  • Suggestions/employee: from 2 to 20.6
    		•
    Sundaram Brake Linings (Warrier 1999; Jagannathan 2002) Brake linings, clutch facings
  • Early & holistic adopter of TQM, TPM & lean practices
  • Initiatives like inviting Daniel Jones to guide implementation
    		•
  • Winner of Deming Prize, 2001
  • Customer rejection rate: from 3000 PPM to 450 PPM
  • Plant rejection rate: from 5% to 1.5%
  • WIP level: 1 day
  • Equipment efficiency: 80%
  • Productivity: 150-200% improvement
  • Scrap: 85% reduction
    		•
    Rane Brake Linings (Iyer & Seshadri 2005) Brake linings, clutch facings
  • Process improvements: quality certifications, TQM, TPM & now Six Sigma
  • JIT delivery to OEMs
  • Kanban & Bin systems for inventory control
    		•
  • Winner of Deming Prize, 2003
  • Customer rejection rate: from 1000 PPM to 100-400 PPM
  • Rework: from 3-5% to 1%
  • First pass yield: from 80% to 95-97%
  • On-time delivery: from 70-80% to 90-100%
  • No. of employee suggestions: from 280 to 7,500
    		•

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    * Contributed by -
    Vaishnav Tadatmya Ashok,
    IIM, Lucknow.
    Send this E-mail this Article

     

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