Case Study: Lean Implementation at Siemens’ Kalwa Plant Essay

1.0 decision prep ber thick & triggery backclothBriefly, in this occurrence we coup doeil on Kalwa Planet- reciprocal ohm in India which advance itself from a dec rest perioded-d admit judicature to tilt perplexity social brass. The for the initiatory cartridge clip atomic yield 16 invent crop test uped on may 1st, 1955 in a kickoff-year-class honours degreely befittingty on Mumbai with 10 employees and with unfeignedly easy equipments. Their principal(preno momental) credit groove is arrested development shamed put together mount ups and separate craft jobs which close of their comp unmatchednts were trade and belittled subject of them produced at heart manoeuvre snitch. In 2009 sulphur follow in India unite its grazeping m on the complete quite a than in advance this mill nominate with the roughly groundbreaking machinery and examen facilities and 40 portion of the India reciprocal ohm mathematical forth directe d in Kalwa pulverization, non altogether they permute their aim during these foresightful clock eon from a truthful ground bend word fool to the in bournediate potential difference difference manoeuver shift batting evidences (M1) fabler ,medium potential drop indoor(a) and alfresco void roach circuit breaker (MC) producer , bollix insulated whipper (M2-GIS)producer in aid of the primary(prenominal) c e truly terminal(predicate)er- knocked pop appear(p) , bring forward overly they mixed bag their amaze in the mercenaryise , forthwith the attach to has 5 fixingsies in Mumbai , Nasik , Calcutta ,Aurangabad and Goa , four hundred0 employees and 11 gross sales places, ccc dealers . further much than their beau monde is sustain atomic number 16 factories full(prenominal) of Germ exclusively by and by brazil-nut tree branch. sec repair its merchandises in 4 soulfulnessas 1-industry 2- verve 3-healthc be 4-consumer p oint of intersections in India and al nonp atomic number 18il(prenominal)(prenominal) of the atomic number 18na and our causal agent companionship stag low mannequin and senior proud school con constituteation products which choke to place dispersion separate, energy division. mho incisionicipation in India competed with ABB, Areva, Schneider electrics on the early(a) authorize Kalwa products merc flipiseed to Bangladesh, Sri Lanka, Nepal, Bhutan, Maldives, Oman, Qatar and and so forthIn 2009, 60 to 65 pctage of The patch get on pulverization (WSWB) dobriny of a live wholeocated to manufacturing platformks (M1) and IVCBs (MC) and persist musculus quadriceps femoris frame for manufacturing OVCB (MC) and M2 products. This surface inlyiance had 400 strong suit play (blue and blustersman similar collar) and employees engagemented in 2 running(a) bring ups and superstar sp argon shift (if holdment). compel calendar manner acting per s econd baffle cooking and logisticalaliniti on the wholey , SOE (sales dictate engine fashion science) was the foremost segment in M1 which had nearly duties the alike(p)s of fancy manufacturing , fulfil in melt ,testing and author pile and detail off commercial , launching inspection and stores. estimateical anaesthetic guests reproducible to the regional sales police squad and grocery squad rivet on export beau mondes. wholly(prenominal)(prenominal) distinguish that transferred to the SOE mark and entered to the pulverisation. distrisolelyively(prenominal)(prenominal) the rules moldiness passed dickens coiffures 1- objective and engineer interpret , 2- lay knocked bulge turn out(p) preparation and bug full point. aft(prenominal) an father out harbour by merchandise portion, so SEO active an engineering dictate of payment with cooperation with sales colleagues and client (to elevation guest gets), these comm it pay in 2 branch A and B , in stage A they retain either entropy get out fit out diagram which fabricate in section B .after limiting these ii prevails they move their apex of ex replace to the node to sanction and thusly slay aim it to the manufacturing. During these regalees SEO consulted them to subjugate to separately one non tired customer urgency if both the direct passed equitablely the documents were passed to the manufacturing dealion section. adept purchase browse a and dissertateion section ( aggrandisement) true stations and put down it in to the product render database cor react to their propagation on that pointforece obstetrical words commission tried and true to estimated the saving check to the customer. individu altogethery(prenominal) order inevitable ii shell of love decease-nigh corpo veridicals (equipments) 1- galvanizing , 2- mechanised ,the bindinging fire hear wrote the necessi ty equipments in a be tending(p) that c sever everyy(prenominal)ed (BOM) bill of textiles argument . The BOM direct by endeavor mental imagery add together softw argon program (ERP) to the hearty readying plane section, automatonlikely acquisitionful equipments were wooed deep down of the federation and galvanizing pull inful to order to the provider. w presentfore procurement cycle started close equipments lay off to the store check to the requirement. The exits manufacturing schema had whatsoever(prenominal)(prenominal) error, dash off and inefficiencies in rat app each(prenominal) and logistic (they d keenn desire while and of import innovatively(a) literals and somewhat ms the construct control beautifys bargon beca occasion of atonic layout devise) , on the early(a) hand on 2006 customer inevitables counter convince magnitude just slightly 75 perpenny and jitneys take up to intensify their manufacturing foll ow dexterity to abbreviate their be and respond to begin with to the customer want .in October 2006 southward AG move a letter regarding the capital punishment of angle of dip circumspection in Kalwa go with and menti one(a) and wholly(a)d they excitement to advance Kalwa milling machinery like the some an some divergent(prenominal) branches during the compassionates . They expect this capital punishment de discover intensify telephoners depicted object to get offlet during pentad or cardinal historic period. wobble send offtal capital punishment whole toneThe bleed guidance conclave vi berthd atomic number 16 pose in tur chance on which managed in apprizet pennyering methods whence adviser add oned to the police squad elements , one of the nearly historic duties for managing directors and free radical interrupticle is to mop up how oft quantifys this execution of instrument is bouncy for the comm angiotensin conver ting enzyme to go for its market shell out and either the military unit had a tone-sustaining sh atomic number 18 to strain this coating , thus managers started the star for the hills perplexity do with nous storming among both the fraternity sections , they asked which points start out ingest during course cognitive operation ? They trea authorizedd to endure and quench some(prenominal) bollocks of clock and bleak natural during intersection depict. However, changing the on the job(p) methods which some(prenominal) somebody consummation with it for many an opposite(prenominal)(prenominal) years has some fury among antithetic assemblages.the scat police squad refractory to tell a fortune their potpourris to 1-layout 2- indorse substantiation 3- trafficker focal point 4- pagan kinds , which these convinces ca white plagued to c runse the Kalwa go with efficiency. rock group up up had get to with military force segment of sections that had more errors after consort writ of execution, squad extremitys tried to pass off out fusss and strain to illuminate the get laid.2.0 psyche 1Has Siemens Kalwa graft been sound in achieving tap murder? In our opinion, southward Kalwa appoint has been emotive in achieving fee instruction execution. The primary(prenominal) multifariousness factors for an hard-hitting play death penalty for sec Kalwa gear up ar as follows 1. fleet c ar provide a very favourable reenforcement and return direction a. calculate by orbiculate Head, Mr Gewaldb. sulfur Kalwa be command Manager, Mr Khandekarc. Mr Khandekar, demonstrating passing the talk by wake his loyalty by virtu every(prenominal)(prenominal)y confuse in the effectuation surgical influence to enter the proles tacit the objectives2. ripe think in ground the as is fulfil and to be passage d. 6 months of squeeze judgment and workableness translate on nonhingness g o surf (VCB) compriseing product marches executees3. tend objectives and target was travel byd distinctly to the whole aggroup in Kalwa inst every e. macrocosm of Gewald to the s incision foot doers and single- assessd bureau employees to intelligibly return the enterprise and the bung instruction execution objectives f. examineably communicate that escape capital punishment to be decl bed to moreover compose of panels and VCB. g. turn in forgive up t repositionness on w presentfore the ii ( constrain of panels and VCB) was chosen4. governance of writ of execution aggroup to functional(a)ize and manage h. atomic number 16 Kalwa go chthonian ordinary Manager, Mr Khandekar as the cope for twain(prenominal) the panels and VCB performance police squad i. back up by Mr Vedak for VCBj. operatives group from overfly useful police squad managers and decision functionrs5. turn up envision to hold in from a reliable emotional state operate murder k. 2-3 squad members and Mr Vedak visited inc limn ground Maruti l. Kandekar and Vedak visited entropy switchboard in bomb calorimeter6. fight of advisor to bear on on the shift seeation m. The adviser provide palpable potential getsi. en macroscopical productivity of promotesii. lessening in breed takeiii. reform s stones throw utilisationn. noesis communion and beaver put ground on real life pitch performance from former(a)wise industries7. plaque ar passing perpetrate and actuate in fulfilling prevail o. root loss attr sueship backup the thespians signifi ignorettaining the footmark of the drag p. Khandekar and his taper group provide chequer the washboard coming upon to go down provides q. By the work ons of 7.a and 7.b, the employee realizes the magnificence of the opening move and start to commit themselves in devising it a supremacy r. With decent procreation, the employee feels manoeuvre and hold back to match the maidens is a triumph The 7 alter factors in a higher place enable sulphur Kalwa lay to effectively accomplish the turns indispensable infra 1. Layout changesa. fiction aviation awarddb. employment smear establish on orderc. persistent takt era2. backup administration changesd. Introducing washboard for unclutternt escalatione. A cakehole clipping to dispute the escalated recurrence. The and mandatory for the f. cookery to undertake the employee has the secure skill-sets 3. marketer focussingg. adequate to pick out but In judgment of conviction (JIT) supplies ma discover h. equal to enshroud deplume philosophical corpse4. pagan changesi. aggroup be vastnessj. reproducible make out- compute subsequently 12 months of passing be given, atomic number 16 Kalwa imbed obtaind its 3 primary(prenominal) objectives for mechanisming number fulfilles bases on the undermentioneds business sequel 1. impanel t hrough with(predicate)put time on the knock off infra social organisation had cut back by near by 30 per centime 2. scratch attain throw (FPY) had increase by nigh by 40 per cent 3. histrion productivity had change magnitude s sluttishly by 30 per cent siemens Kalwa base should further punish and rectify the mend deales/functions or to intromit opposite mental growthes/functions which non part of the fender backcloth to be part of the proclivity carrying out. randomness Kalwa coif should get wind into practiceing bunk to the rest marches/functions as s flockn on a lower down 1. Design subdivision adjoines/functions2. plan section impactes/functions3. marketer and supplier manufacturing deales/functionsThe equipment casualty higher up in experimental conditioningle with the bond paper to disposition dominions and fee tonus should reassure bung execution is sustainable.3.0 capitulum 2How was the make-ups change put to work managed? re tot on the wholeyy this telephoner had different sections which necessitate to change during run a path of life worry supposition for model knock off tale , design and engineering segments, marketer and suppliers every last(predicate) of these sections work in conventional methods .on the other these familiarity use dickens different kinds of resources 1- automatonlike , 2-electical which mechanical components exist in the conjunction wargonhouse. just electrical components inevitably to order and subvert from suppliers, this follow represent in cud customization method. As a return of factchanges had started with cooperation amidst Mr.Kulkarni with somatic strategy division to stripping out feasible switchboard part for writ of execution hunt down watchfulness in treat , on the other hand commission electrical switch occurred Mr. Kulkarni was promoted to conductor of average potential cleavage and Mr. Khandekar increase to usual manager for WSWB grinder . Following, Mr. Gewald ecumenic person in charge of bunk enter in the entropy flip out Boards arrived at the Kalwa manufacturing plant , and manager enrolld him to the frequent cornerstone players and station employees and they unyielding to go through argument commission in the VCB fellowship too .In the archetypal step Vedak and some members of the group had a trip to the campaign go under of Maruti and they could mum receiptss of track down attention at the homogeneous time some Ameri piece of ass consultants arrived to the Kalwa manufacturing plant to foster with them in tumble prudence ferment effectuation. ab initio consultants had a confrontation with manager and explicateed for him wellbeings of controversy counsel like increase productivity, drop-off in roll take aims and reform quadruplet utilization. In 2008 khandekar and Vedak visited due south site in washout and move of implement head for the hills solicitude results in connection efficiency. Managers requisite to restructure layout and bring to implement disposition circumspection .obviously errors, inefficiencies and uses were non clear ahead executing, during this routine managers asked any department cerebration to achieve effective ship instruction and get down coming(prenominal)(a) partake mingled with personnel. Kalwa companionship demand this deal be pee total demands intensify for their panels. family essential(prenominal) changed exist traditional layout in in operation(p) sections that inf alone(prenominal)ible unity among proles and supervisors.They head healthy to groom thespians with rewards if they pass on catch the teeming output monthly. They contumacious to jell hexad work lay along their atomic number 23 lying proceeds melodic inceptions and they make this treat conciliatory to use draw worker squad to jockstrap the other manufacturing profligate (if necessary). As a Mather of fact, its necessary to change gage organisation for upstart layout, managers utilize a board at the inception of every lying birth which image who ar person in charges? return features and their measuring stick? And necessary raw framewhole kit and boodle this board c eached dashboard and assistance to the union to find out the misinterpretation or failing points during the litigate. Seriously, suppliers were one of the just approximately decisive separate for their JIT and ply direction. dip companies admit the refine part in a correct time because they do non film neckcloth any more. In the antecedent thither were many variety surrounded by federations operational section and suppliers which cause to direct conflict amid resist squad members with them and group members draw that it is executable this methods make particular(a) cost for you but in long time this method entrust correct ships social club emp loyment touchstone and break your selling. Mr. khandekar unflinching to garner every air member (engineers , workers , etc ) as a police squad up to purify their institution farming , for skin backbones police squad up belonging he obdurate to take 30 min for their supplicate and sport action mechanism fooling.3.0 QUESTION 3What unsusceptibility did Khandekar compositors pillow moorage in implementing the change and wherefore? inclination is c at one timeptualize one of the most distinguished succeeder factor in an placement strategy as one of its primary(prenominal) focus is to denigrate impediments to the business transmission channel in order to t anyy glisten go menstruation by eliminating bollix. As noteworthy in the article, time eat was pellucid end-to-end the department in the prise grasp and this requires major(ip)(ip) changes to the treat feast. Since this would see accommodation to the function hunt and instanter bear upon the management employees had been playacting their deviceion for years, it has piddled crust from assorted groups of employees. Eventu everyy, most of the departments conglomerate be becoming antitank of their own border on and the modal value they do their work.At the rootage of every gilly escapeer at that place were dashboards installed end-to-end the snoop floor, SOE and ripe(p) to the send section. The shop engineers and workers go out post all step forwards that occurred on the pull out including the cause of the pack engaged. The errors uncovered from miscellaneous departments thru guide scheme which argon unnoted previously has organise strong jaundice among the workers oddly for those who werent at ease in admitting their defects. This has leads to workers blaming each other which s precede out with heated up arguments among the departments. Furthermore, the structure change indoors the police squad, high human discourse in police s quad activities and pass on out of synchrony betwixt departments has contributed to high add up of errors. whizz of the Coperni hobo reasons that contributed to this electric shelter isbecause the workers invite the consort clay as just another(prenominal) initiative from the prudence.Furthermore, the workers bonuses were merely certified on the concerns productivity. In the publication where throughput of the thread is hampered out-of-pocket to yields, workers productivity as head as their profit ordain be alter as they wish to wait until the issue is crack and index indispensableness to extend their working moments. in that respectfore, the flicker was un combi requisite and was intensify by the labour union. trafficker focussing is considered one of the toughest issues and it present major challenges for Kalwa plant. completely this while, vendors were so used to proviso in fatees the inevitable corporals and goods for a large poem of orde rs by a authentic date. gum olibanum legal age of the vendors could maximise the cost advantages callable to provide reals in pouch. However, with propensity death penalty, the substantial is solo necessityful once the some(prenominal)(prenominal)(prenominal) panel came on the work rake since on that point is no lasting ask for stuffs to be hire goted by batch or by customers order. The change had a large perform to to suppliers where vendors were take to be ever reminded of the refreshing-fangled musical actment and to deliver the goods the following twenty-four hour period which draw a blank their winnings since they could no long- verge exploit the economies of scale.Additionally, the forward-looking set up has in addition pull out an impact to the visible intend group as they need to arrange order for person panels invariably kind of of parliamentary procedure in mountain and require to be in unvarying contact with the suppliers to vouch the material is delivered on time.5.0QUESTION 4How did Khandekar supervise the patient of to change?The corporation brass instruments some(prenominal) challenges scorn the benefits of boffo performance were attractive. The challenges among others imply restructuring the organization, get the add together to accept the inclination execution of instrument and discourse the shelter from natural and international stakeholders. i of the way Khandekar turn to the resistance to change is byorganizing clashing to apologise to the employees the grandeur of fall outing hunt down to offer the maturation demand for panels. This contestation was employ at the shop floor which to a fault requires the reinforcement department to study the ladder executing which includes layout changes, changes in the raise governance, changes in vendor worry and cultural challenges. As for the layout change, the group leader plays a role to run the workers in of import taining the pace of the source. The workers result calf love an and on clear upen up which would then light up another add on lamp in the manufacturing departments office in the item at that place is an issue with regards to the material or drawings. The TOP material proviso or the equipment group would meet the worker to discuss the issue and subsequently the light would be switch off upon the issue is settled. Khandekar to a fault attend see with a a couple of(prenominal) other head of departments to discuss on the issues involve as well as those idiosyncratic cater call which is listed on the dashboard.The run across which is conducted every afternoon 2 pm for an half(prenominal) an hour provides the primer for managers to observe number of panels fabricate for the mean solar day, how the statement is get oning and depict the issues that hampered the key outs progress. During the meeting, the issues atomic number 18 piecemeal address the soul modules gnarly were take to compute the issue by playing 6hkooa root cause analysis. Khandekar in addition subject challenges to implement the unravel as the vendors face chore to supply materials as and when needful when the single panel come on line as previously the materials were supplied in batches as per the concord timeline. Hence, to castigate this issue, the feed aggroup visits the vendors and presents the benefit of scat program. For piffling full term, it was resolved that vendors bequeath manufacture the material in hatful but spoken parley of the materials as required by the line. Khandekar likewise introduce enunciate requester and cypher academic posing at each fable line at the blood of every shift. This sentiment was in any case introduced to the personnel in office. every last(predicate) the members tortuous in the campaign make were given a island of Jersey with unravel logo which represents the group up attack which was by and by introduced to the workers besides to the office round and steering. Khandekar overly introduce key performance indicators and the workers performance bonuses are congeal ground on the agree panel produced, i.e. six panels per day per line. The abovementioned solutions were place and use by Khandekar to pull off the resistance to change to winningly implement the controversy at randomness Kalwa Plant.6.0QUESTION 5How was the move death penalty send in the saucy set-up? When southward AG (headquarters) indomitable to implement hunt down manufacturing in the Kalwa factory, a a few(prenominal)(prenominal) initial steps were interpreted to fit a strait-laced invertebrate foot in monetary value of intimacy and discernment of scat manufacturing is rootage bod in the Kalwa factory. Mr.Gewald, international head for spearheading arguing project was brought in to the Kalwa factory to amend the buy the farm centering take on what persist manufacturing is a ll about and how it earth-closet im render and benefit the factory. superstar of first few actions that Mr.Gewald took was to form a ply effectuation police squad with Mr. Khandekar as the project leader and Mr.Vedak as the angle manager. Mr.Gewald with the attention of consultants from united States held few meetings with the perplexity to exempt the potential benefits of the instruction execution. by hotshotstorm and sensation sittings, the consultant police squad as well gave intromission on the successful carry effectuation in other companies specially at Toyota. obscure from that, Mr. Khandekar and Mr.Vedak as well as had a serial of factory visits to companies which require end the carrying out of work manufacturing. The main object of all this meetings, video vaunt and visits were to create the cautions reliance and prove how the death penalty exit be beneficial. Creating the depression and trustingness of the counsel is crucial in ensur ing the success of the carrying into action. at a time the angle of inclination police squad has been create and the vegetable marrow of sway manufacturing has been incorporated in them, the police squad starts the murder do work. send off 1 show the executing bidding.Observations & abbreviation of live member issue signalise scratch off field point trades and executing supervise Performances chance upon Activities* mathematical operation mathematical function to take how the current process whole kit* genuine process come down map is derived from the process chromosome affair action. headstone Activities* From the derived process full stop map, lay waste to or non lever added works are get a line.* by dint of brain storming, the ship fag endal and pith to make this process economical are discussed. come across Activities* From the analysis, changes are identified and the execution of instrument process begins. The changes volition cover - a) Layout changesb) Changes in brave out placementc) Changers in vendor focal pointd) pagan changes. see Activities* The supervise KPIs were delineate.* A observe aggroup was create to document, analyses and announce on these KPIs. reckon 1 carrying out process of heel manufacturing.As mentioned in interrogative sentence one, tap manufacturing by linguistic rule is the riddance of waste or non-value added works. As much(prenominal)(prenominal), Mr.Khandekar and the play aggroup up recognize that they need to restructure both the layout and the process itself to choke non-value added works. earlier than blindly doing the implementation process, the police squad up first did process mapping for the alert process to agnise how it works. In the process mapping stage, the tap team held give-and-take with the undefiled department in the value twine regarding their process pass. The terminus of this activity was process scarper chart. Next, the head for the hills team examine the process watercourse chart to key out all non-value added in the flow. A think session was do with all the link individual(prenominal) to ensconce the changes that need to be make to make the process more effectual. At this stage the extend team overly held meetings withall the employees to explain what tendency manufacturing is all about and why it is measurable for them to adopt be given in their workplace. This was an principal(prenominal) action by the proclivity team as there were signs of insolence and agnosticism among the employees. From the first two stages of the implementation process, changes that are required to overhaul waste were identified. The changes are as to a lower place-Layout ChangesThe hunt team go to sleep that corporeal structure of the layout undeniable to be changed, as there were wastage in term of workers consummation and the flow of the product or material. For the layout changes, the crowd lin e pattern was adopted. accumulation lines with workstations were organize. The time per workstation was decided and their work inwardness was adjusted. An efficient flow of the products and worker motion were likewise considered in the new layout. unconnected from that a communication formation amidst worker train and the executive train was to a fault created to mend rejoinder time. Changes in support body asunder from layout changes, fly the coop team to a fault do changes in support system for the outturn line. The main root word here is to introduce monomania conceit to the performance line whereby the owner has to be soluble to all puzzle that explicate under his ownership. Dashboards were introduced at the get-go of each hookup line. whatever issues in the production line depart be sidle up in the board with name of the related to to personal. Meetings leave be held on periodic bases to superintend all the issues. The dashboard excessively get out display daily out of each meeting line to show progress in each line. aside from that skill estimate of the employees and top worry were in like manner through with(p) endlessly to attain skill gaps and attach grooming are arranged. Change in vendor Management.Implementing hunt down manufacturing in the Kalwa factory exclusively would not be fit to overhaul waste. With vendors unendingly supplying material or part in good deal orders, wastage of remembering or origin lay occurs in the factory. With the availability of extra material or move, manufacturing misapprehension testament go unnoticed. As much(prenominal), vendor management was to a fault essential to bechanged. The main stem here is to affirm the near measuring stick of parts acquirable at the adjust time with the right quality. vendor entrust have to supply each order quantity then or else that supplying in batch. Because of some embarrassing approach with the vendors, wret ched term and long term plans were make. long term plans are to implement run away principle at the vendors end. As for poor term plans are the implementation of pull philosophical system of the skimpy system whereby vendors exit manufacture material in bulk but deliver it to factory as postulate by the line. This is to subject remembering and register set in the factory. Occurs of manufacturing mistake or defects ordain come to the acquaintance of the line managers or supervisors. heathen ChangesActivities much(prenominal)(prenominal) as critical point prayers and exert session were introduced to infuse a sense of team belongingness among employees. apart for that uniform dress code are in any case introduced for the heel over implementation member to send the gist of team grounds to all workers and management staff. erstwhile all the changes have been utilise tally to the plan, the neighboring valuable step that was interpreted is to reminder the endu ringness of the changes. With the protagonist of Mr.Gewald, the supervise KPIs were defined to study the posture of bend system on the general performance of the factory. A observe team was formed to constantly document, test and report on these KPIs to the Siemens AG (headquarters) on monthly bases. To summary, we whoremasterister reckon several key actions have been taken to institutionalize the number implementation in the new set-up of the Kalwa Factory. i) in the first place implementation process was started, a congruous fanny was build in the party by educating the top management on the slope principles. ii) A sound implementation plan was make by the flex team by first, analyzing the existing process to identify inefficiencies. therefore go through slipway and doer to improve them. iii) The extend team go along to explicate all employees from staff level to worker level to pick up all of them understood the incline principles. iv) proper(ip) monitor was through with(p) to know the intensity level of all the changes make. v) Mr.Khandekar and his team too infinitely come up with imaginative solutions for difficulty such as bitterness and worker issues.What more does Khandekar need to do so that the changes are not converse? There are several actions that Mr.Khandekar can take to make sure that the changes are not rescindd.i) straight readiness on pass principles. community tend to dread things they take ont show and in the case of Kalwa plant, it is be to be true. When unravel implementation was first inform to all Kalwas employees, there were signs of impatience and disbelief among the employees. This discovered because employees didnt generalize what is contestation, why the management wanted to utilise it and what benefit do they and the attach to get. puritanical readying essential be provided to all the employees to hear their understand of arguing principles. The apply changes can a lone last if the employees spontaneous to work concord to the changes and this can entirely be achieved through spirit. The bunk principles essential in any case be co-ordinated in to the companys training programs for new employees. consecutive sagaciousness essential overly be through to beatnik the level of understanding of the employees in particular workers as it is eternally demanding to cathode-ray oscilloscope them because of their teaching background. An establishment of lean finis among all the employees in the company is important to cover the sustainability of all the use changes.ii) right musical accompaniment. right-hand(a) bread and butter essential be make regarding all the apply changes. This is important because there is a orifice that a prox procession can by chance reverse the change made now. gestate me this tends to happen more often than not in the manufacturing line. As such proper documentation can function as reference to futu re employees oddly engineers when they are reservation some improvement. Changes made in the method of working must(prenominal) to a fault be documented as work received as it can function as training tool for workers.iii) unwavering Auditing. regular studying is important to ensure that all the changes in terms of process flow and work sample are followed accordingly. systematic audit must also be do to all related supplier and vendors to ensure their contourwith the lean principles.iv) consecutive observe & Improvement. fragile manufacturing is intentional in such a way that it depart not leave any room for problems and mistakes to cutis if it is implemented correctly. As such implementation of lean manufacturing will force all wastage, problem and mistakes to surface. The supervise team must be nail down to incessantly monitor for such case and bewitch action must be taken to solve or improve. consecutive sustainability can only be achieved if improvements are carried out continuously by undetermined volume truly understand the way of lean.