Implementation of Lean concept and performance analysis of manufacturing system using simulation: A case study Moshim G. Mulla, Asst. Prof. Mechanical Engg Dept MBT Campus, Islampur, India mohsinmulla1791@gmail.com Ansar A. Mulla, Asst. Prof. Mechanical Engg Dept MBT Campus, Islampur, India ansarmulla212@gmail.com Mahesh Latte Asst. Prof. Mechanical Engg Dept DYPCOE Kolhapur, India maheshlatte@gmail.com MukundKavade, Assoc. Prof. Mechanical Engg Dept RIT Islampur, India. SudhanvaDeshpande Senior Manager. Emerson Climate tech. Atit, India , Abstract— To days industries striving hard to find methods for low cost, high production in laser time. Lean manufacturing concepts are used by industries to reduce various wastes in manufacturing for competing the global market. This research work has been carried out as a case study at Emerson Climate Technologies (ETC) India Ltd. plant located at Atit with an objective of waste reduction. Effort is made to reduce motion waste in the shop floor by work combination technique. Research work shows house of the simple lean concept and advance simulation software in industry for eliminates non value added activities and operational wastes. Problems in current production line are identified, and analyzed with the help of WITNESS simulation software. Then the layout is modified, simulated and results are compared with current layout. The results show that one operator is elevated than the preǀious. It saǀes in operator’s salary, ǁhiĐh is Đonsideraďle saving in total revenue. Proposed layout successfully implemented in industry and results are validated. Keywords- Lean Manufacturing, WITNESS Software. I. INTRODUCTION Productivity is a measure of the rate at which outputs of goods and services are produced per unit of input (labor, capital, raw materials, etc.). It is calculated as the ratio of the amount of outputs produced to some measure of the amount of inputs used. Productivity measures are used at the level of firms, industries and entire economies. Depending on the context and the selection of input and output measures, productivity calculations can have different interpretations. Improving productivity can have connotations of economizing on the use of inputs for example, adopting efficient production processes that minimize waste. Equally, improving productivity can have connotations of yielding more output for example, using resources in activities or with technologies that generate more output. Moore, a very well known name in the business world, edžplaiŶed plaŶt laLJout as, The plaŶ of oƌ the aĐt of planning, an optimum arrangement of facilities, including personnel, operating equipment, storage space, materials handling equipment and all other supporting services along with the design of the best structure to accommodate these faĐilities. In this research work compressor body machinating line is taken for study. Because this line shows measurable motion waste in time study date and there is measurable improvement by small changes in layout. There are various techniques available to improve the productivity and increasing the revenue of the plant. Reduction of the small wastages during the manufacturing the products is one of them. Waste reduction method is same as continuous improvement. In following section we observed that how lean concepts (reduction of motion waste) increases productivity and revenue of the plant. II. METHODOLOGY Fig 01: Block diagram of methodology followed in this case study Abbreviations Opn – Operation International Journal of Applied Engineering Research, ISSN 0973-4562 Vol. 10 No.61 (2015) © Research India Publications; httpwww.ripublication.comijaer.htm 373