Implementing Lean Manufacturing to the Breaker X Final Assembly Line

Abstract

Abstract - Lean manufacturing is a practice based on preserving the value of a product or service, with the minimum work and materials required to complete it. It is derived from the Toyota Production System and concentrates in eliminating waste and non-value added work while maintaining high standards of quality and customer satisfaction. The implementation of lean manufacturing on any service or production line, can help minimize scrap or idle time, increase productivity, increase sales and returns, maximize infrastructure and time, and produce a quality product that can compete in today’s market. Our company launched a new product into production, but the assembly line wasn’t keeping up with the production needed. The implementation of this practice results in minimal inventory, minimum employee overtime, and higher production while maintaining the standards of quality. The two main outcomes from Lean Manufacturing was 150% increase in production and over $128K in overtime savings. Key Terms - Just-in-Time, Kanban, Lean Manufacturing, Value Stream Map