Pooja Menaria
Independent Researcher
India
Abstract
Application of Lean Manufacturing principles in medium-scale mechanical workshops offers a pathway to reduced waste, improved quality, enhanced productivity, and sustainable competitiveness. This manuscript examines Lean tools—5S, Kaizen, Value Stream Mapping (VSM), Kanban, and Total Productive Maintenance (TPM)—within mechanical workshops established before 2015. A mixed-methods study was conducted in three medium-scale workshops in southern India, combining a survey of 45 operators and supervisors with time-study data on cycle times, defect rates, and machine utilization. Statistical analysis via ANOVA demonstrates significant improvements in cycle time reduction (p < 0.01), defect rate decline (p < 0.05), and utilization gains (p < 0.01) post-Lean implementation. Five research questions guide the inquiry. Identified gaps include limited empirical data on Lean in job-shop environments and challenges in cultural adoption. The paper proposes a structured implementation framework and discusses implications for practitioners and researchers.
Keywords
Lean Manufacturing, Medium-Scale Workshops, Value Stream Mapping, 5S, Kaizen, Cycle Time, Defect Rate, Machine Utilization
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