Performance improvement: a lean manufacturing case of metal tools factory

Lean manufacturing in small and medium enterprises (SMEs) and ultimately success from implementation is marginal as compared to large enterprises. Poor lean implementation technique and understanding is cited as one of the prominent reasons for the low success. Towards bridging this gap, a methodology utilising proper lean diagnostic tools that identify waste and selection of relevant lean tools for future state improvement works is conducted. To further validate the improvement recommendations, the use of discrete-event simulation (DES) is integrated with value stream mapping (VSM) to analyse the effects of improvement measures. A case study was addressed in an SME to improve the production performance and has led to reducing production lead times by 58.5%, increasing process efficiency by 141.28% and cutting manufacturing cost by 51.7%. The research assists decision makers in SMEs that are interested in implementing lean for improving their production performances. Copyright © 2023 Inderscience Enterprises Ltd.