Waste Elimination Using Leantechniques In Gearboxmanufacturing Process

Document Type : Primary Research paper


1 Department of Mechanical Engineering, PSG College of Technology, Coimbatore, Tamil Nadu, India

2 ME Lean Manufacturing, PSG College of Technology, Coimbatore, Tamil Nadu, India


In today's world, shorter lead times and greater customer satisfaction necessitate our preemptive duty of responsiveness. Almost everything is being done faster and just in time, where manufacturers must produce faster without sacrificing quality and deliver to customers on time in order to compete in this globalized world. Manufacturers must find ways to minimize lead-time and costs in order to increase operating efficiency while maintaining the highest level of product quality. To achieve this product diversification, manufacturers must concentrate more on making setup quicker to keep machines running with less idle time and converging to minimize nonadded value activities. Adopting lean tools Single Minute digit Exchange of Die (SMED) and Kaizen can help reduce setup time when transitioning from one product to another. The main goal of this paper is to use SMED method to minimize idle time of machine during setup operation. This study is carried out in a gearbox manufacturing industry. This research work demonstrate the need to overcome most of bottleneck of equipment’s unavailability for resource utilization to run production more efficiently. The projects objective were met, and the change over time was decreased from 80-24 mins (70%), result in improved efficiency and lesser machine idle time. A comparative analysis of the results is then performed using charts and tables to supplement the improvement achieved through the SMED and kaizen approaches. As a result product diversification and production output has increased.