Achieving Operational Excellence through Integrated Approach of Lean Manufacturing and TPM Methodology in Mechanical Cluster Line: A Case Study

The paper illustrates a typical case of developing and deploying integrated Lean-TPM approach to achieve operational excellence in an Indian auto-component firm, emphasizing on ‘sustainable catching-up efforts’ especially after formation of its 50–50 Joint Venture (JV) with a leading Multinational enterprise (MNE).Data collection for eight weeks was done using various charting techniques, TPM-Losses data collection sheets and value stream mapping followed by analysis of basic work content with identification of typical seven MUDAs. Production line was balanced and modified according to Takt-time, TPM-loss reduction Kaizens and performance of line monitored with defined KPIs. Case results reveal that, Lean is a philosophy while TPM is a methodological tool for continual improvement and hence both are mutually interdependent. Integrated roadmap helps to co-ordinate the application of Lean thinking and TPM tools to secure continuous improvement in quality, cost and delivery, by focusing on manufacturing competitiveness. In the context of Indian domestic firms, catching-up efforts through upgrading technological competencies is a popular strategy at beginning of industry evolution after market liberalisation, But development of sustainable competitive advantage by enhancing manufacturing competitiveness is equally important to avoid fates of many Latin American or Eastern Europe transition economies, where stronger domestic firms have lost their country specific advantages (CSAs) and were taken over by MNEs.