A Case Study: Implementation of Lean Tools to Reduce Lead Time in a Cable Manufacturing Company in Bangladesh

Abstract

Every small scale company has an effect on the industrial economy of a country and the world if broadly speaking. Globalization, updating technology, and higher competition have a big impact on small scale companies. These companies need to update their production management methods to reach economic, social and environmental development without making extensive changes. Most small scale companies are even unaware of lean manufacturing tools that exist today. The target of this study is the implementation of ‘Lean tools’ in a small scale company to increase productivity through effective workplace management. The purpose of this study is to understand the effect of lean manufacturing tools like SMED, 5s in plant management, material movement in a cable manufacturing company to understand how productivity and efficiency is changing. The methodologies used in the study are SMED in wire-drawing RBD machine, 5s in workplace rearrangement, plant layout for reducing lead time. The study reveals that lean tools are vital for this cable company. After implementing SMED in wire-drawing RBD machines and optimizing the layout, lead time was reduced by 26% hence profit margin will grow. This literature adds value to the research of lean tools by giving an insight into the implementation of lean tools in cable companies. The tools are implemented only for a static working condition without taking any unforeseen causes into account for delay.