Implementation of lean techniques for sustainable workflow process in Indian motor manufacturing unit

The process of material movement in the motor factory while transference of raw material from the supplier to stock unergonomically designed while loading and unloading using a heavy corrugated box. There is a need for improving the process for a sustainable materials movement and minimizing the material handling wastage. This research study uses a lean principle of manufacturing that is well accepted such as chalk circle exercise (seven mudas of lean principles), by analyzing the spaghetti diagram that minimizes wastes process. To minimize the usage of the corrugated box and deforestation sustainable metallic returnable pallets is ergonomically designed for the material handling. The findings from this research, a reduction of material handling time from 67 hours to 30.1hours per annum was achieved, with physical movement from 152 kms to 117 kms per annum and solid waste from 464 kg to zero. As this research is action research with the corrective action plan and by developing a sustainable returnable packaging that reduced the lean waste in the handling of raw materials at motor manufacturing. The implication of this study is reducing the corrugated packaging material from getting wasted every time by enhancing the material handling productivity and movement of material efficiently with an eco-environmentally friendly product.