Productivity gains through standardization-of-work in a manufacturing company

Purpose The purpose of this paper is to identify the non-value-adding activities (NVAs) of core making process and to eliminate them through the standardization-of-work (SW) procedures in a manufacturing company. Design/methodology/approach The action-research methodology was adopted for the current study. First, various lean tools were identified through literature review, and the bottleneck area was identified in discussion with the shop-floor executives. NVAs were recorded after a continuous process study including method study and motion analysis followed by the standard operating procedure. Second, the standardized work combination tables were prepared and NVAs were eliminated using the SW procedures. SW has been opted because it is a set of actions which helps in analyzing, improving and controlling the process and it leads to continual improvement. Findings The production logbook revealed that the capacity in this particular workstation was 54 pieces per 7 h work shift against the current production of approx. 45-50 pieces (past data). SW saved 31.6 s per cycle which boosted the production up to 58 pieces per 7 h work shift. Finally, the authors came to know that the productivity of this particular process increased up to 6.5 percent which may upsurge if this action is executed continually with the support from shop-floor executives and management. These results were also compared with previous research works in this area and found significant relevance, and hence, the results appear to be reliable. Originality/value The findings of this study are based on the problem formulation for productivity gains using SW procedures in the case company. The study introduces a new perspective for the execution of SW for core making processes. SW created transparency in workflow, enhanced the safety and eliminated the 3Ms. The outcome of the current study was discussed with the production team and management of the company to validate the productivity gains and received an optimistic response. Most importantly, these improvements were achieved with no investment in machinery or tooling.