Implementation of Lean Manufacturing in Aluminium Die Casting Industry

Abstract

This dissertation work aims are to understand the role of lean manufacturing in aluminium die casting and optimum utilization of product. Today market demands for more efficient product at low cost. To fulfil the market demands it is necessary to improve design of product constantly and to decrease its manufacturing cost. Lean thinking is a process which emphasizes on elimination of non-value added services and it augurs maximum efficiency of product Research and Development. Existing process flow of aluminium die casting has been studied to reduce the defect in casting.

Kaizen, 5'S & Value Stream Mapping (VSM) has been implemented in improving the process and plant layout. Kanban is applied in fan department to increase in the productivity. An alternate flow chart has been proposed for equivalent performance. Value Stream Mapping is also applied so to make changes in plant layout. A different type of wastes is being studied and implement in increasing the production quantity. TPM has been studied for the medium scale aluminium die casting industry. TPM implementation methodology is suggested for improvement Overall Equipment Effectiveness in availability, performance efficiency and the quality rate. The aim of this dissertation is to suggest and study the implementation of the TPM program in the Aluminium Die Casting Industry using a JH-Check sheet, PM-Check sheet and comprehensive approach toward the methodology. After implementation of Lean manufacturing on various machines the productivity is increased.