Lean machine manufacturing at Munjal Showa limited

Abstract

Purpose

The global manufacturing industry is becoming more competitive. Munjal Showa, a shock absorber manufacturer in India, is using indigenous development of lean machines by incorporating concepts of lean manufacturing and low-cost automation techniques to increase their competitiveness. This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time. The purpose of this paper is to offer an in depth study of how at Munjal Showa Ltd lean machines are being developed and manufactured. This paper explores how a cumbersome machine was transformed into a lean machine.

Design/methodology/approach

This paper explores how a cumbersome machine was transformed into a lean machine.

Findings

This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time.

Research limitations/implications

The paper discusses the process of converting one cumbersome machine to a lean machine.

Practical implications

Creativity before capital. In lean, team brainstorming of ideas and solutions is emphasized instead of spending large sums of money on capital expenditures

Social implications

The cockpit model eases pressure of incumbents on the shop floor.

Originality/value

The concepts espoused in the paper has increased productivity by 3.45 times and reduced costs.

Citation

Singh Amin, S., Atre, R., Vardia, A. and Sebastian, B. (2014), "Lean machine manufacturing at Munjal Showa limited", International Journal of Productivity and Performance Management, Vol. 63 No. 5, pp. 644-664. https://doi.org/10.1108/IJPPM-06-2013-0120