Application of lean manufacturing in productivity improvement of ‘head lamp leveling switch’ in an assembly line

This research addresses the application of lean manufacturing concepts in assembly line on Head Lamp Leveling Switch used in car as human interface to adjust light beam spectrum according to road slope and load to vehicle. The goal of this research is to find out the methods which can help in increasing the productivity. This research attempts to identify the measure reasons which promote MUDA (waste) and removing those reasons completely or up to a desired level. The ideas will be tested on a large car automotive switch manufacturing company (Mindarika Pvt. Ltd., Manesar, Gurgaon, Haryana). Methods and procedures of this study include a review of literature relevant to Continuous Improvement, Lean Tools and Techniques, and Root cause Analysis, and Assembly process of a specific automotive product (Head Lamp Leveling Switch). After the reasons of waste were identified, solutions and procedures were recommended to Company Mindarika to eliminate wastes in the assembly processes of Head Lamp Leveling Switch.