International Conference on Science and Engineering for Sustainable Development (ICSESD-2017) (www.jit.org.in) International Journal of Civil, Mechanical and Energy Science (IJCMES) Special Issue-1 https://dx.doi.org/10.24001/ijcmes.icsesd2017.41 ISSN: 2455-5304 www.ijcmes.com Page | 22 Review of Lean Manufacturing Implementation: Case of Junction Box Post Processing Phase Vaishali V. Lute, Pranav G. Charkha Datta Meghe Institute of Engineering, Technology & Reasearch, Wardha, India Abstract— In today’s world, competition is very intense in business. Customers are keen towards the quality of the product with timely receipt of products. So it is essential to implement lean manufacturing technique, for better product quality customer satisfaction. We have studied various papers from different backgrounds as listed below in review summary, from the study we have found that how companies use the benefits of lean tools in their conception of lean implementations The different LM tools applied in various industries like Automotive, Bearing, Colour, Pharmaceutical, Aircraft manufacturing, Automobile, Manufacturing & Process Industries were studied with reduced machine downtime, wastages & non value adding activities. This paper aims to propose a suitable LM tool for post processing of Junction box in Discrete Manufacturing environment. Keywords— Lean Manufacturing (LM), Kaizen, Value Stream Mapping (VSM), 5S, Reduction, Lead time, Non Value added activities. I. INTRODUCTION Lean manufacturing techniques are widely used by industries to eliminate waste and make the process more efficient. Lean has been recognized as one of the key approaches in enhancing the productivity and hence the competitiveness of an organization. Lean manufacturing is a Japanese method focused on 3M’s. These Ms are: Muda, the Japanese word for waste, Mura, the Japanese word for inconsistency, and Muri, the Japanese word for unreasonableness. Muda specifically focuses on activities to be eliminated. Within manufacturing, there are various categories of waste. Waste is broadly defined as anything that adds to cost of the product without value addition to the product. Lean manufacturing primarily focuses on i) defect reduction, ii) inventory control, iii) reduced lead time & change over time, Lean manufacturing also reduces the human effort in the factory by over 50%. Lean manufacturing is flexible manufacturing techniques. A number of LM tools can be applied, depending on the requirement in the industry, like VSM was applied in Colour, Bearing, Pharmaceutical & Process industries for addressing non value added activities resulting lead time reduction, change over time & waste reduction. Cause & Effect diagram, Kaizen, 5S were used in automotive MNC industry to reduce machine downtime, wastages & non value adding activities. 5S in auto mobile industry for elimination of waste which is explained in below in literature review. An industry where implementation of Lean manufacturing techniques is yet to be implemented is discrete manufacturing environment. One such discrete manufacturing environment is the post-processing of Junction Box, where the absence of any Lean Manufacturing technique increases lead time, and thereby delaying the supply to target customers. The current study focuses on applying VSM to the Junction Box Industry and reduction in lead time. II. LITERATURE REVIEW Lean manufacturing also reduces the seven types of waste occurring in industry say (a) Transport (b) Inventory (c) Motion (d) Waiting time (e) Over Processing (f) Over Production (g) Defects, with the help of various lean tools according to the requirement. Lean manufacturing tools – The various types of lean tools available are discussed below. 1. 5S 5S creates a work environment that is clean, well organized and efficient. It provides the organization with a rapid, visible achievement, while preparing the workforce for other advanced improvement efforts. 5S is so named for its 5 primary undertakings Sort: Remove all unneeded items from the workplace. Set In Order: Make a place for everything and put everything in its’ place. Shine: Thoroughly clean and inspect everything in the work area (preventative cleaning also applies). Standardize: Maintain the improvements through discipline and structure. Sustain: Continue to support 5S efforts through auditing, job descriptions that include maintenance of the system,