Purpose The core principle of implementing Lean manufacturing is reducing waste through optimum utilization of all resources. In this research paper, the authors have examined the effect of implementing Lean practices on the overall productivity in central India-based manufacturing industries. The purpose of this research paper is to investigate the relationship between the implementation of Lean practices and overall productivity particularly in central India-based manufacturing industries. Design/methodology/approach A model in the integrated form is developed to illustrate how Lean manufacturing practices improve the overall productivity. Based on this model, a survey is performed to validate all hypotheses related to the conceptual model subject to various statistical tests. Findings It is established by the findings of this research that industries based in central India should implement the whole concept of Lean manufacturing practices to improve overall productivity. Industries should adopt the concept of Lean manufacturing in totality, not through the island approach. Originality/value The value of this research paper is to showcase the possibility for central India-based companies to become world-class industries. For this, an approach in the form of an integrated model has been developed.

Effective utilization of the resources is the need of an hour particularly when it comes to the manufacturing industry. It is having a paramount importance to have a proper utilization of the resources, on the same line in any manufacturing industries to reduce the setup time is also one of the ways to do so. Single Minute Exchange of Dies (SMED) is one of the classical method which is normally used to reduce the setup time. In this technique complete videography of the existing changeover is done and then by analyzing it waste activities identified and other improvement plant has been done in each iteration. The chapter also showcases the SMED technique applications in a gear industry. Remarkable resources and results have been achieved through the implementation of classical tool of Lean manufacturing is made.

Today companies are implementing total productive maintenance in order to become world class industries to have a competitive edge over worldwide. In this regard Kobetsu Kaizen (Focused Improvement) pillar having a very significance effect to solve the specific problem. The main aim of this paper is to implement the complete Kobetsu Kaizen methodology of TPM, to solve the issue related with the sudden drop of availability rate of hobbing machine in a gear manufacturing cell. The result of the paper shows the advantage of Kobetsu Kaizen pillar implementation in the sense that breakdown frequency of the machine has been reduced considerably.

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In today scenario, only big companies are not only enjoying the success of lean manufacturing but small and medium enterprise is also adopting the lean practices rapidly. Size of the industries is classified by various ways but most common way is to determine the size of industry through the concept of number of employees on roll in the company. It is the most common parameter to label particular industry whether it comes under the category of large, medium or small. This research paper establishes the relation between size of the industry and use of lean practices in central India based industries.