Aparwal Singh Ahirwar, Mr. Krishna Bhushan Patel



The objective of the research is to identify challenges in an automobile service center and to determine optimal solutions to improve the overall performance. More specifically the research has the following objectives: To increase the productivity using Lean strategy; To reduce the wastage, non-value added activities; To create an easy and simple work environment; To develop a 5S Auditing control system to sustain the improved process; To educate Janitorial level people about benefits of using Lean strategy. The research reported in this research is based on a single case study carried out in an organization using Lean PDCA (Plan-Do-Check-Act) approach, 5S tool and its applications to Increase the productivity. The root causes for the problem in the servicing of cars has been identified through the data based analysis at different stages in the research. The process parameters have been optimized and measured for sustainability in the process. Lean strategy resulted in reduced amount of energy and non-value added activities associated with its production processes. Further, research resulted in the creation of a visual workplace, which has enhanced the production atmosphere, and created a simple and easy process design to lay the foundation to a future of continuous improvement. As a result of this research, the productivity would increase by15 cars/day, which would be a remarkable achievement for the organization. The research provides guidance to organizations regarding the applicability and importance of quality concepts. Organizations need to work continuously with development-orientated activities in order to survive; irrespective of how these activities are labeled. The research will also serve as a basis for further research in this area, focusing on practical experience of these concepts.


Lean Thinking, PDCA, 5S, Maruti Suzuki Automobile Service Industry.

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