Title: Application of Toyota production system for cycle time reduction of Eaton line: a case study

Authors: Mukesh Kumar Barua, Parag Chaporkar, S. Nagarajan, R.A. Malairajan

Addresses: Department of Management Studies, Indian Institute of Technology, Roorkee, Pin-247667, UK – India. ' Medicaps Institute of Science and Technology, A.B. Road, Pigdamber, Rau, Indore – 453331, Madhyapradesh, India. ' Department of Mechanical Engineering, Vickram College of Engineering, Sivagangai, Enathi-653061, India. ' Department of Mechanical Engineering, Anna University Tirunelveli, Tuticorin Campus, Tuticorin, Pin-628003, Tamil Nadu, India

Abstract: The concept of the Toyota production system is known today in the USA as |lean manufacturing|. The basic idea behind the system is elimination of waste. Waste is defined as anything that does not add value to the product from customers| perspective. This paper deals with application of Five-S and Kaizen from Toyota production system for waste minimisation at Eaton line in a medium size manufacturing company. The data collection and analysis resulted in reduction of cycle time of turning machine, broaching, drilling and chamfering, shaping and internal shaping and de-burring and buffing machine. At the same time, reductions in tool search time, material movements and WIP have also been achieved.

Keywords: Toyota production system; TPS; just-in-time; JIT manufacturing; Kaizen; continuous improvement; Jidoka; 5S; sorting straightening sweeping standardising sustaining; cycle time reduction; Eaton line; Japan; lean manufacturing; waste elimination; added value; Five-S; waste minimisation; turning machines; broaching machines; drilling machines; chamfering machines; shaping machines; de-burring machines; buffing machines; machinery; machine tools; search times; material movements; WIP; work in process; customer relationship management; e-CRM; electronic CRM; SCM; supply chain management; decision making; multivariate techniques; customer services.

DOI: 10.1504/IJECRM.2010.036187

International Journal of Electronic Customer Relationship Management, 2010 Vol.4 No.4, pp.415 - 426

Published online: 27 Oct 2010 *

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