ISBN: 978-15-08772460-24

Date: 8.3.2015
PROCEEDINGS OF INTERNATIONAL CONFERENCE ON RECENT INNOVATIONS IN ENGINEERING AND TECHNOLOGY

IMPLEMENTATION OF LEAN CULTURE IN PROCESSING INDUSTRY

V.Prasanth1, S.Sukesh Kumar2, S.R.Mohan Raj3, P.Ramar4, Dr.R.Gnanaguru5
1,2,3,4 Final year Mechanical, Narasus Sarathy Institute of Technology,Salem.
Email: prasanthvbala@gmail.com
5 Professor & Head / Mechanical, Narasus Sarathy Institute of Technology,Salem.
Email: nsithodmech@gmail.com

ABSTRACT
Lean manufacturing is methodology used in
manufacturing industries in order to increase
the efficiency of the processing industry in all
the aspects. This paper deals about the
implementation of lean culture in the processing
industry named SREE RAMA KRISHNA
INDUSTRIES, SALEM using some of the
techniques such as the kaizen, 5-S etc. The paper
also tells the importance how lean culture is an
important technique to be applied in any
processing industry.
Key-words: lean manufacturing, Kaizen, 5-S.
I. INTRODUCTION
Lean principles are derived from the Japanese
manufacturing industry. The term was first coined
by John Krafcik in his 1988 article, "Triumph of
the Lean Production System," based on his master's
thesis at the MIT Sloan School of
Management.[4]Krafcik had been a quality engineer
in the Toyota-GM NUMMI joint venture in
California before coming to MIT for MBA studies.
Krafcik's research was continued by the
International Motor Vehicle Program (IMVP) at
MIT, which produced the international best-selling
book co-authored by Jim Womack, Daniel Jones,
and Daniel Roos called The Machine That Changed
the World.[1] A complete historical account of the
IMVP and how the term "lean" was coined is given
by Holweg (2007).[2]

by Toyota, called The Toyota Way, in which the

focus is upon improving the "flow" or smoothness
of work, thereby steadily eliminating mura
("unevenness") through the system and not upon
'waste reduction' per se. Techniques to improve
flow include production leveling, "pull" production
(by means of kanban) and the Heijunka box. This is
a fundamentally different approach from most
improvement methodologies, which may partially
account for its lack of popularity.
Toyota's view is that the main method of lean is not
the tools, but the reduction of three types of waste:
muda
("non-value-adding
work"),
muri
("overburden"), and mura ("unevenness"), to
expose problems systematically and to use the tools
where the ideal cannot be achieved. From this
perspective, the tools are workarounds adapted to
different situations, which explains any apparent
incoherence of the principles above.
II. DOCUMENT REALITY
The fallowing points are marked as a document
reality when entered the workspace for the first
time.

For many, lean is the set of "tools" that assist in the

identification and steady elimination of waste
(muda). As waste is eliminated quality improves
while production time and cost are reduced. A nonexhaustive list of such tools would include: SMED,
value stream mapping, Five S, Kanban (pull
systems), poka-yoke (error-proofing), total
productive maintenance, elimination of time
batching, mixed model processing, rank order
clustering, single point scheduling, redesigning
working cells, multi-process handling and control
charts (for checking mura).There is a second
approach to lean manufacturing, which is promoted

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Man and Part movement is more.

Cycle time is more due to non-value
adding activity of walking.
Dull lighting over entire workspace.
Existing body of the machine is damaged.
Human effort is more on handling the raw
materials.
Existing Safety system is poor.
Alignment of the electric wire lines is not
proper.
Hammering is used to draw the powder
which is left in pulverizer.
No Surveillance system is used in the
workspace.
No insurance is done to the company.
No modern system is used.
Poor 5-S management.

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ISBN: 978-15-08772460-24
Date: 8.3.2015
PROCEEDINGS OF INTERNATIONAL CONFERENCE ON RECENT INNOVATIONS IN ENGINEERING AND TECHNOLOGY

III. PULVERIZER

IV. IMPLEMENTATION

A pulverizer or grinder is a mechanical device for

the grinding of many different types of materials.
For example, a pulverizer mill is used to pulverize
coal for combustion in the steam-generating
furnaces of fossil fuel power plants. The pulverizer
used in our project is impact type pulverizer.

a.) Powerless Bulb

Figure 2

Objective
The illumination is an important factor for any
industry to promote work with the ensured safety.
Most of the small scale industries today cannot
implement illumination facility in their working
area due to dust, heat etc. So there is a need for the
power efficient methods to promote illumination.
The idea is to trap the renewable energy from the
sun and multiply its effect using solar water bottles.
Figure 1

b.) Machine Body Replacement

The Impact Pulveriser consists of an encased rotor

carrying swing hammers, whizzer classifier for
fineness regulation, and Blower Fan mounted on a
solid shaft. Raw material to be pulverised enters the
crushing chamber through the hopper and
automatic rotary feeder. The impact of the hammer
on the feed material against the Liner plates
reduces it into fine powder. The ground material is
carried towards the whizzer classifier for
classification and the over size particles are rejected
by the classifier and returns to the crushing
chamber for further grinding. The classified
material is then conveyed into the cyclone for
collection and bagging. A dust collector is provided
in the system for ensuring dust Free operation and
no loss of ground powder.

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The machine was originally made up of the steel

body. The pulverizer was subjected to lots of wear
and tear during the process of pulverization. So it is
important to construct the body with the harder
material. The stainless steel is taken as suitable
material
as
an
alternative.

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64

ISBN: 978-15-08772460-24
Date: 8.3.2015
PROCEEDINGS OF INTERNATIONAL CONFERENCE ON RECENT INNOVATIONS IN ENGINEERING AND TECHNOLOGY

time of the process it is replaced with the help of

the trolley.

Figure 5
Figure 3
e.) Use of Trolley
Trolley is used as an exact alternative to replace the
existing manual work. The figure below gives the
use of trolley in the workplace.

c.) Vibration Motor

Objective
The hammer was initially used to draw the remains
of the pulverized powder from the cone. It damages
the outer body of the cone and it also involves the
lot of manual work. In order to replace this process
vibration motor is used as a solution.

Figure 6
V. 5-S IN THE WORKSPACE
Objective
5S is the name of a workplace organization method
that uses a list of five Japanese words:
seiri,seiton,seiso,seiketsu,
and
shitsuke.Transliterated or translated into English,
they all start with the letter S.The list describes
how to organize a work space for efficiency and
effectiveness by identifying and storing the items
used, maintaining the area and items, and
sustaining the new order.The decision-making
process usually comes from a dialogue about
standardization, which builds understanding among
employees of how they should do the work.
a.) Implementation Of 5S
Figure 4

The 5-S is implemented in the workspace and the

figures suggest that the waste is removed and entire
workspace is standardized.

d.) Handling of Raw Material

The raw material was initially handled with the
help of the small carriers taken manually by the
workers. It increases the manual work and cycle

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65

ISBN: 978-15-08772460-24
Date: 8.3.2015
PROCEEDINGS OF INTERNATIONAL CONFERENCE ON RECENT INNOVATIONS IN ENGINEERING AND TECHNOLOGY

The workers are given with the safety mask to

protect themselves from the dust in the processing
center and also the awareness pictures are pasted at
the entire workspace. The figure 23 and 24 suggest
the use of safety mask and the awareness image.

Figure 8
e.) Use of Screener and Hopper
The screener and hopper is also used to increase the
safety in the workspace.
Figure 7
b.) Camera Surveillance System
The camera surveillance system is established to
monitor the entire workspace. The wireless camera
which works on the wireless-Fidelity technology is
used. It also supports android application to
monitor with the help of the advanced android
mobile phones. The figure 21 shows the camera
equipped in the workspace.
c.) Electronic Weight Balance
Figure 9
Objective
f.) Insuring the company
The weight balance used in the workspace is of the
normal type which is manual and time consuming.
It is replaced by the electronic system in order to
reduce the time of usage and is deserved to be an
efficient type.

Insurance is very essential for any industry. The

industry was initially not been insured then the
process of insuring the company with United India
Insurance Company Limited is done.

d.) Safety Measures

Safety Masks and its Awareness

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ISBN: 978-15-08772460-24
Date: 8.3.2015
PROCEEDINGS OF INTERNATIONAL CONFERENCE ON RECENT INNOVATIONS IN ENGINEERING AND TECHNOLOGY

REFERENCE
[1]

[2]

[3]

[4]

[5]

[6]
Figure 10
[7]
VI. CONCLUSION
Thus in this project Implementation of Lean
Manufacturing at the Processing Industry is
completed successfully overcoming all the
problems in the workspace. The manpower and
work associated with it is reduced and new
improvements in the workspace are developed. The
safety measures in the industry are also developed.

[8]

[9]
FUTURE SCOPE
In future, the automatic loading and unloading
system can be used in the workspace. The AGVs
to be used on handling the raw materials in the
workspace. The surveillance system is to be used in
the entire processing industry. The mixer should be
used replacing the manual proportionating. The
entire system should be computerized and use of
the counters to calculate the number of bags.

[10]

[11]

[12]

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