Lean Production and Automotive Industry UK Assignment

Added on - 18 Sep 2019

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The Lean Production inthe automotive industry ofUKDissertation ReportABC[Pick the date]
AbstractThe ‘Lean Production’ is a practice to reduce the inventory of the shop floor in a manufacturingfirm. It aims to zero down the defects, setup time, breakdowns, handling, lead time and surging.The primary aim of this research is to understand the ‘model of lean production system’ alongwith its application in the automotive industry of UK. This research is descriptive as it describesthe characteristics of the variable which is being studied i.e. the lean manufacturing. It will helpin studying the topic in depth, and it will also be able to describe the process of leanmanufacturing in the automotive industry of UK. The data has been collected using thesecondary sources only. There is immense literature available on this topic which will be studiedin this case. The literature on the process of lean manufacturing, its principles, application, etc.has been studied, and hence the project has been done. The data will be analyzed with the help ofcomparing and contrasting the information collected from the secondary sources. Theunderstanding level of the researcher will be used to analyze the data and hence draw theconclusions for this project. The data has been analyzed with the help of comparing andcontrasting the information collected from the secondary sources. The understanding level of theresearcher will be used to analyze the data and hence draw the conclusions for this project. It hasbeen found and concluded that ‘Lean Production’ is a practice to reduce the inventory of theshop floor in a manufacturing firm. The origins of this concept lie in the history of the Japanesewho carry out the manufacturing activities on the policy of tight material control, and thus theyaim to achieve such a production which is "stockless." This means that they aim to reduce theinventories to the minimum possible level and mainly to the "zero" level. The specific tools andtechniques that help in the production and implementation of lean manufacturing are cellularmanufacturing, continuous improvement, just in time, production smoothing, work1
standardization and total productive maintenance. Apart from initial cost of installing, there is noother drawback that has been identified related to the lean manufacturing. Hence, the system hasmore advantages than the disadvantage.2
ContentsChapter 1: Introduction....................................................................................................................51.1 Aim.........................................................................................................................................71.2 Objectives...............................................................................................................................71.3 Research Questions................................................................................................................81.4 Research scope.......................................................................................................................81.5 Problem Statement.................................................................................................................81.6 Research rationale..................................................................................................................9Chapter 2: Literature Review.........................................................................................................112.1 Introduction..........................................................................................................................112.2 History of lean manufacturing.............................................................................................122.3Review of the concept of the lean production system..........................................................162.4 The models and techniques of lean in the automotive industry of UK................................202.5 Effectiveness of lean production in automotive industry of UK.........................................262.6 Process of lean production...................................................................................................302.7 The pros and cons of lean production system......................................................................34Chapter 3: Research methodology.................................................................................................383.1 Type of research...................................................................................................................383
3.2 Data collection.....................................................................................................................403.3 Source of data collection......................................................................................................413.4 Data Analysis.......................................................................................................................443.5 Supervision...........................................................................................................................453.6 Support used.........................................................................................................................46Chapter 4: Analysis of data............................................................................................................47Chapter 5: Discussion and interpretation of Results.....................................................................53Chapter 6: Conclusions..................................................................................................................586.1 Recommendations and proposals for further work..............................................................59References......................................................................................................................................61Appendices:...................................................................................................................................694
Chapter 1: IntroductionThe ‘Lean Production’ is a practice to reduce the inventory of the shop floor in a manufacturingfirm (Shah, 2003). The origins of this concept lie in the history of the Japanese who carry outthe manufacturing activities on the policy of tight material control, and thus they aim to achievesuch a production which is "stockless." This means that they aim to reduce the inventories to theminimum possible level and mainly to the "zero" level. It is also known `as seven zeros. It aimsto zero down the defects, setup time, breakdowns, handling, lead time and surging (Melton,2005). Thus, the companies that target lean production strive to achieve a zero inventory, andthey do this by production what is required and when it is required. With this, the storage costsget eliminated along with the possibility of the capital being tied up in the inventory.The approach of the lean manufacturing is used so that the non-value added activities could betransformed into the value added activities. The technology that is used in the leanmanufacturing has its own impetus, and it focuses on the entire operation. There are allemployees who are involved with the methods of lean manufacturing, and this concept has thedirect influence on the attitudes of the people that are a part of the company. The businessenvironment of the companies is very competitive these days, and the companies try very hard tosurvive in that competition. They have to remain competitive in the environment no matter what.In this process, if the companies get an opportunity to cut their cost, then it is very beneficial forthem. With the lean manufacturing methods and technology, the businesses get the goldenopportunity to downsize their costs, the lead time of the customers and cycle time too. there aremany companies in the country UK that are already using the lean technology , but still, thereare some areas that are yet to be permeated by the companies (Detty, 2000). Though the5
technology is very useful, but still there are some challenges that are faced by the companies likethe lack of scale, the amount of investment made in the technology and infrastructure etc. tosafeguard the interests of all the people and companies in the economy, the government of UKmust maintain the standards of quality and they must help the companies in implementing thetechniques in the systems of the company.The projects related to lean management are launched in the companies with great enthusiasm.The process starts with the appointments of the project leader and then he helps the company indeveloping a vision for the future to all the team members. The team has to develop the aimsregarding how they have to make their company a lean factory. The source for these technologiesis no single; there are many techniques for this. For example, this concept has roots from thedays of Taylor and Henry ford. The techniques of lean manufacturing were then improved by thecar manufacturers of Japan. The Japanese developed the systems of Kanban material handling,and then the same concept was reintroduced in the western world with different terms like theToyota production system, the Just –in-Time concept and the Kanban manufacturing.There are many scientists and researchers who have worked on this topic previously likeDeming, Taylor, Skinner, etc. and hence the principles of the lean production are new, and theycan trace back to the work of these people (Pavnaskar, 2003). The models and the application ofthe lean production are understood from this literature which the previous researchers havegiven. But, the concept became popular when the study on the Japanese auto industry as carriedout. It became clear after that, and then it got extended to the entire spectrum of activities in thebusiness and to companies, particularly the automobile industry and the electronic companies.Though there have been some voices that discontent the lean production because they doubt the6
effectiveness of the lean manufacturing, but it has been observed that companies are changingtheir methods of production and the management practices to become leaner.This paper discusses the process involved in the lean production system in the automotiveindustry of UK of the UK, the models, and techniques of lean in the automotive industry of UKof the UK and the prospects and constraints of the lean production system in the automotiveindustry of UK. This will help in getting an overview of how this concept has traveled fromJapan to the UK and how much it has helped the automotive industry of UK. For knowing this,the philosophy will focus on collecting the information for this concept ad developing apragmatic view that will help in improving the lean manufacturing activity in the UK.1.1 AimThe primary aim of this research is to understand the ‘model of lean production system’ alongwith its application in the automotive industry of UK.1.2 ObjectivesThe main objectives are as follows:To identify the condition of UK’s automotive industry before and after implementation oflean production practices.To identify and study the models and techniques of lean in the automotive industry ofUK.To identify the process in which lean production works for automobile industry of UKTo appraise the pros and cons of lean production system on the automotive industry ofUK in the UK7
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