Background
Lean On Us partnered with India’s largest independent manufacturer of Rear Drive Axle Assemblies to improve manufacturing efficiency through work standardization and Lean principles. With plants in Pant Nagar and Jamshedpur, the company has been producing Medium & Heavy-duty Drive Axles, Front Steer Axles, Non-Drive Axles, Axles for Defense & Off-Highway applications, and Drum & Disc Brakes for over 30 years.
Challenges
Through an in-depth assessment, Lean On Us identified key inefficiencies affecting productivity and cost-effectiveness:
✅ Lack of Standardized Work: Absence of documented processes led to bottlenecks, resource wastage, and increased costs.
✅ Labour Cost Misalignment: Overstaffing in some areas and understaffing in others led to excess costs and inefficiencies.
✅ Material Handling Inefficiencies: Poor factory layout and workflow design resulted in delays and operational disruptions.
Lean On Us Approach
1. Standardized Work Implementation
A structured Lean Six Sigma approach was applied to implement standardized work:
- Process Documentation: Comprehensive step-by-step work procedures were created, detailing work sequences, cycle times, and quality standards.
- Work Standardization Framework: A robust framework was developed to minimize errors, reduce waste, and optimize workforce efficiency.
- Employee Training Programs: Standardized work instructions were introduced, ensuring consistent processes and faster onboarding.
2. Line Balancing & Manpower Optimization – Pinion Cage Assembly
To improve production efficiency, Lean On Us used a dual-pronged strategy:
1️⃣ Reorganization of Elemental Work & Task Combination: Workflows were analyzed and rebalanced to eliminate redundancies.
2️⃣ Kaizen for Process Optimization: A Kaizen event was conducted to reduce Ram movement by adjusting the home position, significantly improving efficiency.
Additionally, cross-training programs were introduced to increase workforce flexibility, ensuring seamless task execution and optimized manpower allocation.
3. Line Balancing & Layout Modification – Differential Case Assembly
The production line was further optimized by:
✔ Redistributing tasks to eliminate bottlenecks.
✔ Reconfiguring the gear heating station layout to improve workflow and reduce material handling inefficiencies.
✔ Upskilling the workforce to adapt to the revised production process effectively.
These changes resulted in reduced delays, streamlined workflows, and enhanced throughput.
4. Driving Sustained Change
To ensure long-term success, Lean On Us implemented continuous improvement strategies:
📌 Comprehensive Process Analysis: Every task and workflow was reviewed to identify optimization opportunities.
📌 Work Standardization: Clear SOPs (Standard Operating Procedures) were created to drive consistency and efficiency.
📌 Kaizen & Employee Engagement: A culture of continuous improvement was cultivated by encouraging employee-driven process enhancements.
📌 Real-Time Data Tracking System: A digital loss tracking system was deployed to monitor inefficiencies and implement corrective actions instantly.
This systematic approach reinforced a culture of Lean thinking and continuous operational excellence.
Key Results
The Lean implementation delivered tangible improvements:
✅ 21-manpower reduction, optimizing workforce allocation.
✅ Output efficiency increased from 68% to 95%.
✅ Eight process improvement Kaizens successfully deployed.
✅ Real-time data tracking system implemented for loss monitoring & action planning.
Conclusion
By implementing Lean Manufacturing, Standardized Work, and Line Balancing, Lean On Us transformed the Drive Head Assembly Line into a highly efficient, cost-effective operation. This initiative not only streamlined workflows and reduced waste but also established a culture of continuous improvement, ensuring sustained operational excellence.