Work Standardization Study for Identifying and Improving Critical Work Stations using Lean Manufacturing Concept - A Case study on LCV Assembly Shop

Author (s):

  1. Sahebagowda, B V B College of Engineering & Technology, Hubli, Karnataka, India
  2. V.N.Gaitonde, KLE Technological University, Hubballi
  3. Vinayak N Kulkarni, KLE Technological University, Hubballi,


The lean manufacturing technology is most effective and efficient manufacturing concept which is used to improve the productivity with high quality. Based on lean manufacturing concept, the project is carried out in LCV assembly shop at one of the reputed automobile companies located in North Karnataka-India. Work standardization study is carried out and motion study is made by using Yamazumi sheet, Standardized work combination table (SWCT) and Standardized work sheet (SWS). Based on data collection number of line stoppages per day in assembly stations are identified. Among those stations critical station is being identified and using lean tools like kaizen and 5s techniques the improvements are made in those critical stations to reduce cycle time and number of line stoppages per day. The Ergonomics study and analysis is carried out as a part of this case study project to know how kaizen improvement reduces Work-related Musculoskeletal Disorders (WMSDs). After improvements in critical station. Non value adding activities are reduced and therefore 4% of cycle time is reduced and number of line stoppages per day is reduced by 33% in LCV assembly shop.

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