RESTRUCTURING THE MANUFACTURING PRACTICES IN THE SURGICAL INSTRUMENTS INDUSTRY OF SIALKOT TO LEAN MANUFACTURING1

Abstract

Lean manufacturing practices are the modern day practices of the management of wastes in all forms that exist within the system. This methodology puts emphasis on the flow of value by the use of various tools and techniques. The transition to lean has become a fast growing trend worldwide, because of the results that it produces. This research is aimed at the evaluation of lean practices in the surgical instruments industry of Sialkot. Furthermore, the study moves along the path of practicality by guiding the implementation scenarios and requirements for the Lean Manufacturing in the surgical Instruments Industry of Sialkot. The criterion for choosing these modern manufacturing techniques has been explained and the benefits as enjoyed by those who have adapted these techniques have been brought to light. An extensive literature review has been carried out, based on this literature review, an implementation procedure, mapped especially for the target industry has been presented. The basic aim of this research work was to find out the gap that exists between the current and recommended modern practices of the target industry. The findings and recommendations are based upon the results obtained from an extensive questionnaire, interviews and on site observations with the most senior and most qualified personal of the companies situated in the target industry. According to the statistical results and pre- existing research work, all the companies should adapt the Lean manufacturing practices in order to accomplish the desired financial and business goals. A very important and rarely acceptable concept that this research work brought to the consideration of the target audience is that the explored and recommended modern practices are only successful once implemented completely and practiced with a regular routine. These practices put emphasis on the increased involvement of the customers, the employers and suppliers in the designing and manufacturing phases. The ultimate objective of introducing the Lean practices is to improve the productivity of the target industry. In order to ensure that the objective is met successfully, the guide for implementation has been developed in the “implementation” chapter. During the research work and visits to the industries of target sector, huge wastes in the form of time, material and products were observed. All the companies follow same processes and practices for the manufacturing of similar products e.g. in the manufacturing of scissors. These wastes are not visible to most of the managers and hence they are working to make progress in the competitive age of modern practices, with their non efficient systems. This research work will ensure reduced wastes and much broader perspective of the range of products with no wastes. The findings of this research work have brought to the conclusion that the traditional practices and methodologies have become obsolete in the modern markets and that, these practices are holding the industry back in competing against the international competitors. Lean practices act as the key to remain competitive and progressive in the modern markets and to achieve the satisfaction of the customer.