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Implementation and Analysis of True Lean in a Startup Company by Using Pdca Model, a Case Study in a Manufacturing Venture University of Kentucky UKnowledge Theses and Dissertations--Manufacturing Systems Engineering Manufacturing Systems Engineering 2019 IMPLEMENTATION AND ANALYSIS OF TRUE LEAN IN A STARTUP COMPANY BY USING PDCA MODEL, A CASE STUDY IN A MANUFACTURING VENTURE Ankit Jangid University of Kentucky, [email protected] Author ORCID Identifier: https://orcid.org/0000-0002-4833-4785 Digital Object Identifier: https://doi.org/10.13023/etd.2019.423 Right click to open a feedback form in a new tab to let us know how this document benefits ou.y Recommended Citation Jangid, Ankit, "IMPLEMENTATION AND ANALYSIS OF TRUE LEAN IN A STARTUP COMPANY BY USING PDCA MODEL, A CASE STUDY IN A MANUFACTURING VENTURE" (2019). Theses and Dissertations-- Manufacturing Systems Engineering. 9. https://uknowledge.uky.edu/ms_etds/9 This Master's Thesis is brought to you for free and open access by the Manufacturing Systems Engineering at UKnowledge. It has been accepted for inclusion in Theses and Dissertations--Manufacturing Systems Engineering by an authorized administrator of UKnowledge. For more information, please contact [email protected]. STUDENT AGREEMENT: I represent that my thesis or dissertation and abstract are my original work. Proper attribution has been given to all outside sources. I understand that I am solely responsible for obtaining any needed copyright permissions. I have obtained needed written permission statement(s) from the owner(s) of each third-party copyrighted matter to be included in my work, allowing electronic distribution (if such use is not permitted by the fair use doctrine) which will be submitted to UKnowledge as Additional File. I hereby grant to The University of Kentucky and its agents the irrevocable, non-exclusive, and royalty-free license to archive and make accessible my work in whole or in part in all forms of media, now or hereafter known. I agree that the document mentioned above may be made available immediately for worldwide access unless an embargo applies. I retain all other ownership rights to the copyright of my work. I also retain the right to use in future works (such as articles or books) all or part of my work. I understand that I am free to register the copyright to my work. REVIEW, APPROVAL AND ACCEPTANCE The document mentioned above has been reviewed and accepted by the student’s advisor, on behalf of the advisory committee, and by the Director of Graduate Studies (DGS), on behalf of the program; we verify that this is the final, approved version of the student’s thesis including all changes required by the advisory committee. The undersigned agree to abide by the statements above. Ankit Jangid, Student Dr. Jeffrey Seay, Major Professor Dr. Fazleena Badurdeen, Director of Graduate Studies IMPLEMENTATION AND ANALYSIS OF TRUE LEAN IN A STARTUP COMPANY BY USING PDCA MODEL, A CASE STUDY IN A MANUFACTURING VENTURE ________________________________________ THESIS ________________________________________ A thesis submitted in partial fulfillment of the requirements for the degree of Master of Science in Manufacturing Systems Engineering in the College of Engineering at the University of Kentucky By Ankit Jangid Paducah, Kentucky Co- Directors: Dr. Jeffrey Seay, Associate Professor of Chemical Engineering and Dr. M. Abbott Maginnis, Associate Professor of Mechanical Engineering and Director of Lean Graduate Certificate Program Paducah, Kentucky 2019 Copyright © Ankit Jangid 2019 https://orcid.org/0000-0002-4833-4785 ABSTRACT OF THESIS IMPLEMENTATION AND ANALYSIS OF TRUE LEAN IN A STARTUP COMPANY BY USING PDCA MODEL, A CASE STUDY IN A MANUFACTURING VENTURE The purpose of this research is to implement and analyze the true lean transformation in a manufacturing start-up organization. Often, lean transformations are observed in developed manufacturing organizations having sophisticated production lines and numerous employees, where lean tools are utilized to reduce waste while increasing profit. However, this type of transformation is narrowly focused on quantifiable process results and falls short of the ultimate goal, establishing a true lean culture within the organization. As a result, it is recommended that true lean principles, philosophies, culture, operations environment and tools be applied at the very beginning stages of an organization, or during the start-up phase to embed true lean thinking and application in the entirety of the organization. In this analysis, a case study is performed on a team embarking on a start-up manufacturing enterprise. The team is trained on true lean and all the four aspects of true lean are applied for successfully implementing true lean in the start- up. In addition, true lean implementation approach was generated and applied using PDCA (plan, do, check and act) model. The results of this case study are presented in this work. KEYWORDS: True Lean Principles & Philosophies, True Lean Culture, True Lean Operations Environment, True Lean Tools & Terminologies Ankit Jangid 04/24/2019 Date IMPLEMENTATION AND ANALYSIS OF TRUE LEAN IN A STARTUP COMPANY BY USING PDCA MODEL, A CASE STUDY IN A MANUFACTURING VENTURE By Ankit Jangid Dr. Jeffrey Seay Co-Director of Thesis Dr. M. Abbot Maginnis Co-Director of Thesis Dr. Fazleena Badurdeen Director of Graduate Studies 04/24/2019 Date I dedicate this thesis to my wife and my parents ACKNOWLEDGEMENTS First, I thank God for the many opportunities that have allowed me to pursue my Master’s degree at the University of Kentucky. I acknowledge my parents’ support in sending me abroad to pursue my goals and dreams. I also thank my wife for her steady support and encouragement throughout the process. Thank you for allowing me to discuss my ideas with you and receive feedback for generating this document. Because of your love, I have achieved this milestone. I further acknowledge the guidance of my advisors, Dr. Jeffrey Seay, Dr. M. Abbot Maginnis and Dr. Fazleena Badurdeen. Their input, assistance, and expertise have allowed me to create a meaningful thesis. From them, I have gained valuable knowledge and skills in the field of manufacturing and True Lean. Their courses, one-on-one discussions and feedback on my work has allowed me to truly understand this fields, which I hope will further benefit others too. iii Table of Contents ACKNOWLEDGMENTS ............................................................................................ iii LIST OF TABLES ........................................................................................................ vi LIST OF FIGURES ..................................................................................................... vii LIST OF ABBREVIATIONS & ACRONYMS ....................................................... viii 1. INTRODUCTION.......................................................................................................1 1.1 Problem Statement .................................................................................................2 1.2 Objective ................................................................................................................3 1.3 Research Question ..................................................................................................4 2. LITERATURE REVIEW ..........................................................................................5 2.1 Background ............................................................................................................5 2.2 Lean Manufacturing ...............................................................................................9 2.3 A Journey from TL to Sustainability ....................................................................17 2.4 Startup ..................................................................................................................20 3. METHODOLOGY ...................................................................................................22 3.1. First Aspect of TL: Principles and Philosophies .................................................24 3.2. Second Aspect of TL: Culture .............................................................................30 3.3. Third Aspect of TL: Operations Environment ....................................................33 3.4. Fourth Aspect of TL: Tools and Terminologies ..................................................39 4. APPLICATION OF TRUE LEAN IN TSPC, A MS (CASE STUDY) ................47 4.1. Value Proposition ................................................................................................48 4.2. Functional Product Prototype ..............................................................................48 4.3. Product Market ....................................................................................................48 4.4. Potential Customers and Customer Demand Forecast ........................................49 4.5. True Lean Training ..............................................................................................51 4.6. PDCA Model for Applying Four Aspects of TL .................................................53 5. DISCUSSION OF RESULTS ..................................................................................74 6. CONCLUSION .........................................................................................................78 iv APPENDIX....................................................................................................................80 A.1 True Lean Exam Results .......................................................................................80
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