Development of a Productive Work Cell through integration of Work Study and Lean Tools - A Case study on a Leading Tire Manufacturer in Sri Lanka

Abstract

Globalization has paved the path to a rapid growth of world economy while increasing both market competitions of scare resources. Thus, this has raised a paradox for the businesses to consume resources more efficiently and effectively to seize the competitive advantage with a productive growth. Work-study techniques provide tangible solutions while enhancing the efficiency and effectiveness in both service and manufacturing sectors. Accordingly, lean tools provide the foundation to confirm and endure the productivity concepts. Therefore, this paper provides an in-depth description of a case study in improving the level of productivity and effectiveness while developing a flexible work cell in a leading Tire Company in Sri Lanka. In the content of this study, a grey tire manufacturing process has been analysed in terms of work measurement to develop a flexible work cell through workload balancing and lean tools like 5S, Root cause analysis etc. Correspondingly, the contribution of this study has enabled the Final preparation cell of the Grey tires to increase the cell productivity from a level of 43.75 units/mhr to 70units/mhr. In conclusion, the results of this study confirmed, that work-study and lean tools could work collaboratively to produce a highly productive and efficient system in a Sri Lankan manufacturing entity.