Lean philosophy: implementation in a forging company

This research addresses the implementation of lean philosophy in a forging company with a focus on radial forging production flow lines. Here, the prime motive is to evolve and test several strategies to eliminate waste on the shop floor. In this research, a systematic approach is suggested for the implementation of lean principles. This paper describes an application of value stream mapping (VSM). Consequently, the present and future states of value stream maps are constructed to improve the production process by identifying waste and its sources. Furthermore, Taguchi's method of design of experiments is pursued here to minimize the forging defects produced due to imperfect operating conditions. A noticeable reduction in set-up time and work-in-process (WIP) inventory level is substantiated. Finally, we conclude with a discussion of managerial implications and the future scope of research.