Design and Implementation of Pennar Integrated Management System (PIMS) Model Through Lean Principles and Practices

Now a day's traditionally operated discrete manufacturing industries are facing serious problems like lower machine and manpower productivity, longer production lead time, Low yield high rework, poor line balancing, lack of standardized work process and performance measurement system for the employee, high work-in-process, low production capacity, high labour (operator) absenteeism, high rework and poor resource utilization are among others. Lean is an optimized manufacturing approach that aims to streamline the flow within an organization. Today lean is not solely limited to the continuous process manufacturing industry, companies with discrete manufacturing facility are increasingly adopting and modifying lean strategies and practices to suit the needs and thus streamlining their processes. The primary topic of interest in this paper is to improve productivity through quantitative research methods and different lean manufacturing tools such as value stream mapping (VSM), standardization of work process, line balancing, and 5S and to address the solutions.

The case studies illustrate the application of LEAN tools, their sustainability and effectiveness in improving the overall operational performance by elimination/reduction of wastes (Muda) in our organization. The following LEAN tools are applied-5S, Value stream mapping (VSM), KAIZEN-Continuous Improvement, Integrated management systems methods(ISO methods), Productivity based manpower planning, KAIZEN improvements, Quality circles, suggestions schemes.