PRODUCTION MANAGEMENT USING LEAN PRINCIPLE (OBEYA)

Abstract

Production assembly line is a very critical and important area of an industry as every product is unique and has distinctive manufacturing processes after the minor changes of difference in raw materials, work order machining, on floor bottleneck issues and others limitations. There are different production practices carried out by small and medium enterprises based on different production factors like Quality, Raw material shortage, Work order monitoring, Production time, and less revenue. Similarly, OBEYA is a lean engineering production technique pioneered by Toyota production system and later adopted in range of automotive industries. OBEYA; a Japanese word focuses on enhancement of production performance and tools along with feedback from the departments. In this research, an empirical study was conducted using a process control tool on an industry, prior to and after implementing OBEYA. On completion, the results were analysed and compared. The analysis of production was carried out using statistical process control (SPC) methodology. Statistical Process Control (SPC) is used to bind the variation between the permissible tolerances, as it is impossible to eliminate variation from any process. This Paper discusses planning and implementation of SPC with lean technique (OBEYA) so that it contributes to create unique production system and eliminate the perception of OBEYA to be purely origin as automotive industries. The results of the approach supports the methodology developed and implemented in a case industry producing ceiling fan.