Enhancing manufacturing competence using lean manufacturing techniques

Abstract

TITAN is today's undisputed leader in the quartz analog watch segment in the country with a market share of 42 %. After having parted ways with Timex, the corporate strategy has now shifted from the high priced to the low and medium priced segments. In the post liberalisation era, relaxation of foreign policies has seen a spurt of players Hoe SITCO, Maxima, Ajanta, in the low priced segment and foreign brands 8% Citizen in the medium and high priced segments. Free trade not being a distant dream, competition is expected to hot up. Titan has realised that it is high time to re-engineer its manufacturing activities and introduce lean manufacturing techniques, to focus on reducing cost and improving speed and flexibility. The main objective of this project is to study the existing manufacturing configuration at the Watch Assembly and Case Plant and implement lean production systems. Though the process of change has been taking place for some time now, it has been isolated and without following a logical sequence. Through (his project we have systematicaly approached the lean production system like shortening set up time, multi-skilling, cellular manufacturing and Kanban system At this juncture it is heartening to indicate that the Kanban system is already implemented in one of the movement assembly lines (for calibre 5120). Framing cells and single piece flow with a motorised conveyor line is expected to be the next step in the ladder approaching lean manufacturing. Lead time at Watch Assembly and Case Plant are expected to crash by about 50 % consequently leading to a savings of Rs.145 lakhs. This study also helped us to meet the business plan for the next 2 years.