International Journal of Innovative Technology and Exploring Engineering (IJITEE) ISSN: 2278-3075, Volume-8 Issue-11, September 2019 2915 Published By: Blue Eyes Intelligence Engineering & Sciences Publication Retrieval Number:K22050981119/2019©BEIESP DOI:10.35940/ijitee.K2205.0981119 Abstract: Productivity Improvement has become an important goal for today’s automotive industry, as the customer demand is increasing every day. Organisation takes this as an opportunity to improve the business potential. Implementation of lean manufacturing tool results in productivity improvement and cost reduction in several companies. There is a strong correlation between productivity and labour productivity. Labour productivity improvement has a direct impact on business growth. This article presents a case study on application of lean manufacturing tool “Eliminate Combine Rearrange Simplify (ECRS)” in the manufacturing industry. This work is carried out in a medium scale automotive parts manufacturing company where all kinds of machining operation is taken place and the output of the product is supplied to vehicle manufacturer. This case study is illustrating increase in labour productivity in an automobile component machining line by applying the ECRS technique. Vertical Machining centre, Combination of tool, man and machine concept is used for implementing ECRS technique in the machining line. After implementation there is significant increase in labour productivity and reduction in throughput time and saving of space on the shop floor. Keywords : Eliminate Combine Rearrange Simplify (ECRS), Vertical Machining Centre, Throughput Time, Labour Productivity. I. INTRODUCTION Systematic management practices such as lean production promote improvements in productivity and reduce unnecessary waiting time during the manufacturing process and increase quality and speed. [1] Usage of latest technology for manufacturing will reduce the throughput time. Investment in production techniques have a positive effect on productivity through reduction of personnel expenses, increased outputs, reduced costs and increased flexibility. The technique of seeking improvement for increasing productivity by verifying the necessity of work elements is Eliminate Combine Rearrange and Simplify- ECRS. [2] Among these four principles the Combine technique has been used in frozen chicken producer to Revised Manuscript Received on September 06, 2019 A.Pradeep, Department of Mechanical Engineering, Vel Tech Rangarjan Dr.Sagunthala R&D Institute of Science and Technology, Chennai., India. A.pradeep2005@gmail.com A.Manimaran* Department of Mechanical Engineering, Vel Tech Rangarjan Dr.Sagunthala R&D Institute of Science and Technology, Chennai., India.. Email: mullaimaran@rediffmail.com P.Arun Kumar, Department of Mechanical Engineering, Vel Tech Rangarjan Dr.Sagunthala R&D Institute of Science and Technology, Chennai., India. Email: arunkumarp@veltech.edu.in K.Balaji, Department of Mechanical Engineering, Vel Tech Rangarjan Dr.Sagunthala R&D Institute of Science and Technology, Chennai., India. Email:kbalaji.me@gmail.com combine job A and B which reduces the manpower. [3] For productivity improvement in a drinking water production plant, equipment has been used to combine the product at the packing stage for the ease of putting film on the water bottle, which has reduced the cycle time and increased the productivity. [4] For manpower reduction in a pasteurized milk manufacturing organisation, job done by two workers was reduced to one. [5] Production rate has been improved in a horn assembly line by combining two machines performing pre and final crimping process in a single machine. [6] So far the combine technique has been used to combine two machines, two jobs and two operations. Labour productivity is calculated to measure the efficiency of men. There is a high degree of correlation between labour productivity and business performance. [7] Labour productivity is the ratio of total production volume to the total number of labour. Based on the volume of production the type of machine to be installed is decided which in turn influences the plant layout. Proper utilization of factory floor space depends on the plant layout. Production quantity can be estimated by available working time in a shift. Available working time in a shift is calculated by subtracting various allowances from the total working time in a shift. These allowances are provided to compensate the worker for the production interruptions that may occur due to his personal legitimate needs or the factors beyond his control. [2] Shows that allowances such as Personal allowance 5 %; Fatigue allowance 5 %; and Delay allowance 5 %. As a total Personal Fatigue and Delay allowance - PFD comes to 15. The available working time is used to measure the takt time and cycle time. Cycle time varies from machine to machine. Machining centers are numerically controlled machines with multipurpose machining capabilities such as milling, drilling, boring, tapping, reaming, turning and grinding. Vertical machining centers have a vertical spindle where setup and handling are easier. This flexibility not only provides productivity improvements and throughput time reduction but also allows one machine to replace several single purpose machines or machining processes. Lean metrics like throughput time, cycle time and takt time are important when analysing and making decisions regarding a production system. Throughput time is the time a product takes to flow through the process, from start to finish. Cycle time is defined as the time taken to complete a task. Takt time is the ratio of available working time per shift to the customer‟s demand rate per shift. Labour Productivity Improvement in an Automobile Component Manufacturer Machine Shop using Lean Tools A.Pradeep, A.Manimaran, P.Arunkumar, K.Balaji