The objective of this research is to improve the overall result and pass percentage of students in degree level technical institutions by eliminating the failure causes using lean six sigma method. A case study was carried out in a degree level technical institute, which has a total intake of 720 students producing 54% of results for the past five years. Taking as a challenge issues to produce more than 75% of results, it was considered to carry out a study using lean six sigma approach. In this research five stage methodology of six sigma i.e. DMAIC have been used to reduce the parameters that affect the system. Failure mode effect analysis, histogram, process capability analysis and fish bone diagram methodologies were also adopted to analyze the depth of the issue and to identify the critical factors that requires to be controlled and to improve by implementing the solutions and remarks received from the stakeholders. From the results it was found that, through this approach the pass percentage level of the technical institute had increased from 54% to 75% by identifying and reducing the appropriate source of failures.

The objective of this research is to implement the lean techniques over CNC machine cells with standardization and line balancing for reduction of overall lead time. The methodology used for this research is a combination of traditional lean system with ZF production system. The analysis was carried out over CNC machine cells with the objective of standardization and line balancing of the cells. Primarily the standardization of the CNC manufacturing cells were done, so that the process is streamlined and optimized without non-value added activity. Also this study deals with productivity improvement in manufacturing line through continuous improvement using kaizen approach. Observation of cycle time was carried out by video based work study technique. The operational videos such as cycle time of various processes were captured and improvement possibilities were identified. Then line balancing was done to overcome bottlenecks between operations to meet customer TAKT time and to increase overall productivity. The overall output has been improved from 22 to 30 per week for all models of gear box. Lean tools such as standard work procedure and Kaizen were employed and found that the overall cycle time was reduced by about 609 minutes with an improvement of 17.54%.

In recent engineering practices, the manufacturing industries are more technically able to produce product with high quality to desire the customer needs. For accomplishing customer needs many lean tools are used to improve the methods of manufacturing practices in industries. The aim of this research work is enhance the productivity of spool casing assembly used in horn armature core per shift by using method study, time study and VSM. Cycle time for each operation of the product is determined by time study and the value added, non-value-added activities and transportation wastes occurred in the current state process identified and plotted in the current state VSM. The future state VSM was developed to reduce unnecessary wastes such as transportation, inventory, waiting which occurred in the current state VSM. Both current and future state time study are simulated using Flexsim simulation software. From the observed results it was found that, P3 and P5 model productivity was improved by about 5.5% and 6.5% respectively after implementation of appropriate lean tools.

In current scenario, all the manufacturing industries are placing constant efforts for their endurance in the current global volatile economy. Manufacturing industries are annoying to implement new and professional techniques in their regular production processes. Some of the recognized tools are applied and their awareness has been growing among the industries, especially in production sector. Last two decades have witnessed an explosion in the area of quality and productivity improvement initiatives in the manufacturing industries by different tools and techniques such as lean manufacturing, total quality management, total productive maintenance, six sigma implementation etc. The objective of this study is to enlighten the importance of lean techniques implementation in a medium scale belt manufacturing industry. This research study helps to exhibit the existing hidden potential in the selected industry as well as a selection of appropriate techniques for productivity improvements. Also, it aims to eradicate wastes and non-value added activities at every stage in order to enhance the overall productivity. From the results after implementation of appropriate lean techniques it was found that, the lead time was reduced about 1256 minutes and the overall production was increased by about 9%.

Recently, aluminum alloys are extensively used in automobile and aeronautical industries due to its low density and excellent mechanical properties. The aim of this research work is to focus on develop an aluminum matrix composite reinforced with boron carbide particulates under different weight percentages by squeeze casting route. To obtain better results, it is essential to control the process variables involved in the process. The primary work focused to optimize the process variables involved in the fabrication of the composites using full factorial design. The experiments were carried out with various input parameters like squeeze pressure of 50, 100 and 150Mpa, melting temperature of 700, 750 and 800°C and weight fraction of reinforcement of 6, 8 and 10% using L27 orthogonal array. The significant parameters were identified by analysis of variance table and regression analysis was used to model the mathematical relationship for obtaining better mechanical properties. Final results reveal that, mechanical properties of 218VHN hardness and 412MPa tensile strength had been obtained based on the optimum combination levels. Also AA7075-B4C composites produced through this route with enhanced properties could be used as an alternative material for high strength structural applications like connecting rod, control arms, steering knuckle and other parts.