PROJECT PRESENTATION ON

LEAGILTY :-INTEGERATING LEAN AND

AGILE MANUFACTURING PARADIGMSCASE STUDY

PROJECT MEMBERS:RAHUL AGRAWAL

MUKESH KUMAR
SUYASH BARTARYA
SUYASH SHUKLA

UNDER GUIDANCE
OF:DR. SURENDER KUMAR
MR. MANOJ AGRAWAL

GENERAL PROBLEM STATEMENT

In the manufacturing process, there are so

many wastes that can affect the profit of the
business. Waste is defined as anything that
does not add value to the end product from
the customers perspective. The
manufacturer must minimize the waste
during producing the product so that the
profit of the business can generate highly
and the production cost can be minimized.
The main task in this case is to implement
leagile methodology in production so that
the waste can be eliminated.

PROBLEM OVERVIEW IN INDIAN

INDUSTRY
The bad news is that in spite of more benefits, leagile
manufacturing in India is still in infancy stage and the
Indian firms are far away from enjoying its complete
benefits. The awareness level of Indian firms on lean
manufacturing is very low. The concept is largely
adopted only by the big firms. One such example is Tata
Motors which has created a success story by launching
Nano implementing lean manufacturing. Lean and agile
philosophy helped to reduce the cost without
compromising on size and comfort. Recently many
apparel firms have also opted for lean manufacturing
owing to reduction in order-to-delivery time from
European importers.

But Small and Medium Sized Firms (SMEs) in

India are still mostly unaware of lean and agile
principle. The lean and agile principles cannot be
implemented exactly the same in every industry
and therefore the Indian firms need to chose
proper tools and techniques according to the
work culture, infrastructure availability and
working conditions of specific industry. Further,
most Indian firms lack the human resources
commitment on acceptance of a new philosophy.
The implementation of lean philosophy demands
a motivated and trained work-force and
committed top management which is not
available in most Indian SMEs even today. The
competition is very tough and lean and agile
principles can prove very beneficial for the Indian

BACKGROUND OF CASE STUDY

The study was to identify the problems that normally
occur at a MSME company which is ATV PROJECTS PVT.
LTD. based on the LEAN AND AGILE manufacturing
perception and provides the suitable methods or tools
that can be applied with less cost and time to overcome
them. A small and medium enterprise company was
chosen as most of them are generally still use the
traditional method of processing due to lack of technical
information, expertise and also finance. So, with the
identification of problems and the solutions that were
provided in this study, they will benefit the company to
improve their production system, processing and their
response towards change

METHODOLO
GY

What is Leagility ?
Leagility= leanness + agility
Leanness: emphasis cost reduction, waste removal; maximize
profits and service via proper schedule.
Lean production is a philosophy for optimizing the performance
of the organization in all functional areas, by utilizing the
resources in a more efficient way and eliminates waste.
Agility: emphasis service -total flexibility - maximize profits via
providing exact customer requirement at minimum cost.
Agile manufacturing is a term applied to an organization that has
created the processes, tools, and training to enable it to respond
quickly to customer needs and market changes while still
controlling costs and quality. Agile manufacturing is seen as the
next step after Lean manufacturing in the evolution of production
methodology
In manufacturing theory being both is often referred to as leagile.

Lean, Agile and Leagile

supply

Towards a Satisfied Customer:

Input

Input

Input

Cost
Reduction

Lean processes

Customer
Service

Agile processes

Lean
proces
ses

and

Agile
process
es

Total
Value

ADVANTAGES OF LEAGILE
MANUFACTURING
MASS
PRODUCTION

LEAGILE
PRODUCTION

BASIS
Peopledesign

HENRY FORD

TOYOTA, US(AGILE)

Narrowly skilled
professionals

Teams of multi-skilled
workers at all levels
in the organization

People-Production

Unskilled or semiskilled workers

Teams of multi-skilled
workers at all levels
in the organization

Equipment

Expensive, singlepurpose machines

Production Methods

Make high volumes

of standardized
products

Manual and automated

systems which can
produce large volumes
with large product variety
Make products which the
customer has ordered

Philosophy

Aim for good

enough

Aim for perfection

About company
ATV PROJECTS LTD.- ATV Projects India , a
company incorporated to take over Anand Tanks
& Vessels (P) Ltd, engaged in the business of
executing turnkey projects. The amalgamation
was effective from Sep.'87. Presently the
company is engaged in execution of turnkey
projects and supply of equipment for several
industries such as Sugar, Fertilizer, Chemical,
Petrochemicals, Steel, Power, Nuclear Power etc.
by manufacturing the part of the equipments
and components at its plant at Mathura

CASE STUDY OF NOZZLE

Observation
Total time estimated on making
product(nozzle)= 246hrs
(calculated)-Value added time
Actual time= 45(days)*8(hrs/day)
= 360hrs
Non value added time=360-246=114
hrs
We are going to reduce this time by
lean and agile principles for which
some techniques are to be applied.

Plant Specification
Two shop floor area for operation.
Shop floor area= 11000sqm
Vessel Manufacturing Unit: Covered area= 8316sqm
Largest size of job can be
accomodated
Height= 19m
Diameter= 25m

Shop floor1 layout

Ladder making section

Shop floor2 layout

PROBLEMS IN SHOPFLOOR IN ATV

FACTORY
Large amount of scrap machines are there which are not in use
and they are just reducing space of shop as you can see on layout
Improper material distribution
No proper paint section
Material handling is not proper
No proper inventory storage in shop floor.
Jumbled flow or a disconnected or intermittent line flow
Low production density and underutilization of plant capacity.
Lack of flexibility in the plant production facilities.
Long processing time due to too many delays, temporary storage,
bottle-necks etc.
Improper utilization of plant site including inaccessibility to the
rail road siding wasted outdoor area etc.

DIFFERENT DEPARTMENTS IN
A.T.V.
1. House keeping
2. Inventory
3. Technology
4. Maintenance
5. Time
6. Process Capability
7. Production Process &Equipments
8. Human potential
9. Energy
10. Material
11. Communication & I.T.
12. Design

Performance index

Performance index is an estimate of

the process capability of a process
during its initial set-up.
An operational performance index
measures the use of economic
resources, production output and
employee productivity.

Formula for calculating

performance index
PI= Total
Rating(Calculated)
Maximum Rating
1. Process Capability:PI=0.65
2. Technology:PI= 0.73
3. Communication & IT:PI= 0.68

4. Material:PI= 0.665
5. Time:PI= 0.614
6. Human Potential:PI= 0.47
7. Energy:PI= 0.624
8. Maintenance:PI= 0.61

9. Production Process/ Eqpt.:PI= 0.625

10. Inventory:PI= 0.607075
11. Design:PI= 0.6187
12. Housekeeping:PI= 0.7714

FINDINGS AND RESULTS FROM

ANALYSIS:-

Cumulative performance
index
Cumulative PI= Total performance index of
all deptt.

Total no. of deptt.

Calculated Cumulative PI=

63.88%

The cumulative PI is not up to date so it means that

industry wants that some lean and agile tools must be
applied. By inspection, we have also seen that
company is also not upgraded in various sectors like:communication and it, insufficient and absence of
material handling equipment, improper housekeeping,
lesser and minimum use of R&D facilities etc. In case
study of nozzle we have also seen that there is a lot of
non-value added time, this time does not add value to
customer as well as industry. So, lean tools application
is must. We already know that any change in Indian
MSME sector create trouble and disturbance in all
departments so proper philosophy of change must be
implemented for this so that manufacturing system
become flexible to show the readiness of enterprise for
changes in demand and supply.

Recommended plant layout

Advantages of new plant

layout
As shell is the common part for both the shops so there is a
common section for that this will reduce the space in shopfloor and
allotment of material, men and machine is well distributed.
Common store bi-directional to supply the inventory to both shops
and fulfilling the mutual requirements.
Scrapzone is made to store that material which can never be used
for reducing wastage in shopfloor and this is thrownout
further( Dustbin approach)
Recycling and Reuse zone will check and sort those material and
machine which can be used again and it will send it to the inventory,
otherwise it will goto scrapzone.
Minimize the waste by filtering approach.
Reduce inventory at shopfloor
Proper inventory and stock management can be possible.
Fast movement of material and better flow

5S technique is most suitable

for ATV
It is the technique most suitable for ATV as there is large amount
of scrap material as machines, material. There is no proper paint
section in both of the shops, random distribution of all the things
and improper management. So, for this 5s technique is best
suited.
5S is a system to reduce waste and optimize productivity through
maintaining an orderly workplace and using visual signals to
achieve more consistent operational results The term refers to five
steps sort, set in order, shine, standardize, and sustain that are
also sometimes known as the 5 pillars of a visual workplace. 5S
programs are usually implemented by small teams working
together to get materials closer to operations, right at workers
fingertips and organized and labeled to facilitate operations with
the smallest amount of wasted time and materials.

Implementing the 5S method means

cleaning up and organizing the
workplace in its existing configuration.
It is typically the first lean method that
organizations implement. This lean
method encourages workers to
improve their working conditions and
helps them to learn to reduce waste,
unplanned downtime, and in-process
inventory.

EXPECTED BENEFITS

Lead Time (Cycle Time) reduced by

9%
Productivity increased by 5%
Work-In-Process Inventory reduced
by 8%
Quality improved by 8%
Space Utilization reduced by 7.5%

CONCLUSION
In

the era of globalization, all the

organizations try to improve
productivity and quality using all the
industrial engineering tools. Leagile
manufacturing is a dominant tool
which is proven globally as one of the
best tool available to improve overall
operating efficiency.

THANK YOU