Application of Lean Manufacturing in Automobile Industry

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Acknowledgement

I would take this opportunity to thank my research supervisor, family and friends for their support and guidance without which this research would not have been possible

Declaration

I [type your full first names and surname here], declare that the contents of this thesis represent my own unaided work, and that the thesis has not previously been submitted for academic examination towards any qualification. Furthermore, it represents my own opinions and not necessarily those of the University (Katzenbach, 1993,, 111).

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Abstract

This thesis is a theoretical evaluation of two popular corporate initiatives Lean. While corporations try to implement this method, they face some fundamental barriers. The problem statement in this thesis recognizes these fundamental barriers and addresses some of the major issues that exist in its implementation. A very thorough literature review was conducted on all the available written literature on Lean. Lean's relationship to other initiative tools was provided to develop a context. The study aims to understand the concept of Lean and its implementation in the holistic sense. It gauges the benefits, challenges and consequences of the Lean idea in the organization

TABLE OF CONTENTS

ACKNOWLEDGEMENTII

DECLARATIONIII

ABSTRACTIV

CHAPTER 1: INTRODUCTION1

Introduction1

Research Aim2

Problem Statement2

Research Objective2

Research Question3

Electronic data base searches3

Layout of the Report3

CHAPTER 2: LITERATURE REVIEW7

Introduction7

Lean Method7

Lean Tools and Principles10

Benefits of Lean Production12

Application of Lean16

Lean and the Organizational Context18

Lean in Automobile Industry22

CHAPTER 3: METHODOLOGY26

Research Approach26

Research Strategy27

Research Philosophy27

Data Synthesis28

Research Design29

Data Extraction Strategy29

Data Collection and Analysis Method30

Qualitative Method31

Qualitative Research32

Ethical Consideration33

Literature Search33

Validity34

CHAPTER 4: DISCUSSION AND ANALYSIS36

Lean Management in the Upcoming Years38

CHAPTER 5: CONCLUSION AND RECOMMENDATIONS40

Conclusion40

Recommendations42

Future of Lean43

Chapter 1: Introduction

The subject at hand pertains to the discussion of the application of lean manufacturing technology in the automobile industry. This investigative study undertakes the discussion in a much detailed manner and through a comprehensive research. Long with the discussion of the various applications of lean, the study also undertakes to elaborate upon the present scenarios of the usage of lean, the difficulties faced in the implementation and also presents the appropriate solutions for the future adaptability of lean in the organizations.

Introduction

Lean manufacturing is the American name for the Toyota Production System (TPS). It is one of the most advanced manufacturing concepts available in the market today. Many progressive companies like General Electric, Honeywell and Motorola have implemented Lean Manufacturing in various areas of their businesses and enjoyed the benefits.

Japanese Sensei, who is Ex-Toyota employees, has been responsible for spreading Lean concepts around the world. Various US companies were exposed to Lean manufacturing after the book Machine that changed the world, (Womack, 1991) was published and since then have increased their understanding and utilization of the subject. During the period that Lean Manufacturing was becoming popular, another quality movement, Six Sigma, was occurring in industry. Motorola introduced Six Sigma in the late 1980s. Today Lean and Six Sigma are the more popular quality movements in industry. Six Sigma is an initiative that provides a highly focused management-sponsored project approach to the rapid improvement and cost control of selected ...