A case study to improve the productivity of ladle gearbox manufacturing

Gearbox manufacturing company was confronted with the problem of only being able to produce seven gear boxes per month, rather than the projected twelve gear boxes per month. A process-oriented approach was used by the organisation. Further research revealed that the procedure requires a substantial amount of time that is not used to create value (i.e., transport time, waiting time, quality rework time, poor work environment and poor inventory management). Company decided to employ lean tools to boost the product’s production rate by eliminating as many wastes as possible during the production process. The layout was altered from a process to a cellular pattern as part of the project. 5S techniques were then implemented, which enhanced the working atmosphere while also giving employees a greater sense of control over the machine they were using. At long last, the company put in place an inventory-reduction Kanban system, allowing it to go from batch production to JIT manufacturing.