To: Anand James From: Shalak Joshi Date: 31 January 2014 Subject: Research synopsis Proposed Research Topic:

Study of Lean Manufacturing Techniques and Effects of

implementing Lean Manufacturing using VSM in a Small Scale Industry

Purpose: Lean Manufacturing (LM) is a practice which focuses on reducing work and preserving value. It is being accepted and implemented by major companies worldwide with substantial results. The aim of this project is to understand the various elements of LM, to implement LM in a small scale industry using Value Stream Mapping (VSM) and to study the effects using quantitative data. Background: The primary aim of this project is to study and understand the principles of LM. The study will incorporate understanding how LM is implemented in companies like Toyota, Ford, DHL, etc. with special focus on VSM. My aim is to implement LM in a small scale company using VSM based on the initial study and research. This will be accomplished by studying the current state of production, conducting a value stream analysis and proposing & implementing changes to the system. Data collected before and after the implementation will be used to analyse the effects of LM and form conclusions. Scope: The primary research on the principles will be conducted from 1st of February till 21st of February. This will include studying books and case studies on LM. Field work will be conducted in the company from 25th February till 31st March, wherein data will be collected, analysed and changes implemented. The results after implementation will be collected during the first week of April. The analysis and conclusions will be formed by 10 th of April. The field work will include observational research and interviewing the workers and supervisors of the company. Theoretical framework: LM consists of various practices and principles and each practice has been widely explored and studied in major companies like Toyota, GE and Ford. I will focus on the literature and case studies elaborating on the practical applications of LM in these companies. I plan to

focus on the VSM technique as it is a relatively simple tool which I can test practically. Studying VSM will help me to understand the fundamentals of LM such as, types of wastes, Kaizen, JIT, etc. Method: The steps involved during this process are: 1. Conduct a literature review on LM. Study cases for various companies and application of LM. 2. Focused study of VSM, tools used in VSM and its practical application. 3. Observation of processes in company for one week to map the as is state of value stream. 4. Observational research and interviews of workers to collect quantitative and qualitative data such as process maps, lead times, cycle times, types of wastes, procurement methods, inventory handling methods, etc. 5. Analyse the as is value stream and compare it to the ideal value stream to identify areas for improvement. Highlight major areas of improvement and evaluate various options for improvement by involving work force. Conduct discussions and note down feasible solutions possible. 6. Suggest improvements, gain approval from company management to implement changes in the value stream. Interact with workers and supervisors and explain the various changes to be implemented. 7. Map the changed value stream and collect data. 8. Conduct comparative analysis of before and after data and draw inferences and conclusions. 9. Prepare a report which highlights my understanding of the theoretical aspects of LM, its practical application and the results. Reflect on the advantages and benefits of LM and also limitations and problems faced. Timetable: Registration: January 31. Synopsis: January 31. First project review: February 22, 2013 Field study review: March 15 Second project review: March 29 Report submission/ Viva: April 12, 2014

Limitations: The duration of the trimester may limit the time for application of LM in the company. Exposure to the complete value stream may not be achieved due to the focused nature of the project. There may be limitations in terms of the data shared by the employees and executives of the company. Certain appropriate assumptions will have to be made based on industry standard practices. References: 1. Grewal, C. (2008) An initiative to implement lean manufacturing using value stream mapping in a small company, Int. J. Manufacturing Technology and Management, Vol. 15, Nos. 3/4, pp.404417. 2. James P. Womack & Daniel T. Jones , LEAN THINKING 3. http://www.lean.org/whatslean/ 4. http://www.mindtools.com/pages/article/newSTR_44.htm