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Study on Enhancement of Quality Level through a Lean Approach in an Original Equipment Manufacturer

In the present condition, customer demand has increased gradually due to technological development and globalisation in this world. So this made the industrialist to deliver the products at right quantity at right place at right time with shorter lead time. But due to high rejection rate the industries fails to meet the customer demand which in turn reduces the customer satisfaction. Hence, this research an attempt was made to reduce the defects of casting components in an original equipment manufacturer. The study was carried out in a foundry of brake drum manufacturing industry. The problem was inside that the industry could not meet the customer demand due to high rejection rate and the major contributor for high rejection is found to be sand drop. Hence, proposed solutions have been implemented to achieve the objectives. After implementation of proper lean tools it was observed from the results that, the rejection rate was reduced by about 4% and the quality level was increased by about 4.4%.