COMBINED APPLICATIONS OF LEAN MANUFACTURING AND OSH IN LEATHER MANUFACTURING PROCESSES

摘要

Introduction The leather manufacturing process involves intensive manual laboring and there are copious opportunities to apply modern tools such as lean manufacturing for improved productivity and reduced occupational stress. The aim of the work is to assess the feasibility of extending the combined applications of lean manufacturing principles and OSH studies in a leather manufacturing unit in India. Method The lean manufacturing techniques used in this study are time and motion measurements. The ergonomic hazards as a result of work postures were independently assessed and later compared with the time-motion studies. The project involved the collection of videos of the various operations at the leather manufacturing unit. The collected videos were analyzed and the data obtained were compiled in the form of operation charts and time study sheets. Results The time taken for each element has been calculated and a table has been constructed for multiple cycles. The time taken for each operation when all suggestions have been implemented is estimated to give an idea of the time that can be saved. This resulted in a saving of 79.82 secondsand 15% reduction in the total movements throughout the entire process. Based on the sequence of operations followed for the two products produced in the largest quantities (nappa and suede), suggestions for modification of the plant layout have been provided. The proposals aimed at increasing the efficiency of the plant while keeping the costs involved in modification of plant layout to a minimum. An effort has been made to place consecutive operations as close together as possible in order to decrease transportation time and reduce manual labor handling. Conclusion This study has made a number of useful suggestions which if implemented, would result in higher productivity, worker safety, decreased worker fatigue and a more efficient usage of work space. This study can be considered a useful starting point for the modernization of the Indian leather industry as a whole.