A FRAMEWORK FOR LEAN IMPLEMENTATION

USING LEAN LABORATORY SOFTWARE

APPLICATION IN THE INDIAN MATTRESS
MANUFACTURING INDUSTRY.
A PROJECT REPORT

Submitted by

ROSHAN RAJKUMAR S (20BME4064)

in partial fulfillment for the award of the degree of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

M.KUMARASMY COLLEGE OF ENGINEERING,KARUR

ANNA UNIVERSITY: CHENNAI 600025

APRIL - 2024
M.KUMARASAMY COLLEGE OF ENGINEERING,KARUR
(Autonomous Institution affiliated to Anna University, Chennai)

BONAFIDE CERTIFICATE

Certified that this project report “A FRAMEWORK FOR LEAN

IMPLEMENTATION USING LEAN LABORATORY SOFTWARE
APPLICATION IN THE INDIAN MATTRESS MANUFACTURING
INDUSTRY” is the bonafide work of “ROSHAN RAJKUMAR S
(20BME4064)” who carried out the project work during the academic year 2023
– 2024 under my supervision. Certified further that to the best of my knowledge,
the work reported herein does not form part of any other project report or
dissertation on the basis of which a degree or award was conferred on an earlier
occasion on this or any other candidate.

Signature
Dr.M.Loganathan M.E, Ph.D
HEAD OF THE DEPARTMENT,
Department of Mechanical Engineering,
M.Kumarasamy College of Engineering,
Thalavapalayam, Karur - 639113.
Signature
Dr.M.Mohan Prasad M.E.,MBA.,Ph.D.
SUPERVISOR,
Department of Mechanical Engineering,
M.Kumarasamy College of Engineering,
Thalavapalayam, Karur - 639113.

This project report has been submitted for the end semester project viva v oce
Examination held on ______________

INTERNAL EXAMINER EXTERNAL EXAMINER

ii
 DECLARATION

We affirm that the Project titled “A FRAMEWORK FOR LEAN

IMPLEMENTATION USING LEAN LABORATORY SOFTWARE
APPLICATION IN THE INDIAN MATTRESS MANUFACTURING
INDUSTRY,” being submitted in partial fulfillment of the award of Bachelor
of Engineering in Mechanical Engineering, is the original work carried outby us. It
has not formed the part of any other project or dissertation on the basis of which
a degree or award was conferred on an earlier occasion on this or any other
candidate.

Student name Signature

1. ROSHAN RAJKUMAR S (20BME4064) -------------------------

Name and signature of the supervisor with date

iii
 ACKNOWLEDGEMENT

Our sincere thanks to Thiru. M. Kumarasamy, Chairman and Dr. K.

Ramakrishnan, B.E, Secretary of M. Kumarasamy College of
Engineering for providing extra ordinary infrastructure, which helped us to
complete the project in time.

It is a great privilege for us to express our gratitude to our esteemed

Principal Dr. B. S Murugan M. Tech, Ph.D for providing us right ambiance
for carrying out the project work.

We would like to thank Dr. M. Loganathan M.E, Ph.D, Head,

Department of Mechanical Engineering, for their unwavering moral support
throughout the evolution of the project.

We offer our whole hearted thanks to our internal guide Dr. M. Mohan
Prasad M.E, Ph.D, Associate Professor , Department of Mechanical
Engineering, for her/his constant encouragement, kind co-operation, valuable
suggestions and support rendered in making our project a success.
We offer our whole hearted thanks to our project coordinator Dr. R.
Balamurugan M.E..,Ph.D, Associate Professor Department of Mechanical
Engineering, for her/his constant encouragement, kind co-operation, valuable
suggestions and support rendered in making our project a success.

We glad to thank all the Teaching and Non Teaching Faculty Members of
Departmentof Mechanical Engineering for extending a warm helping hand and
valuable suggestions throughout the project.

Words are boundless to thank Our Parents and Friends for their constant
encouragementto complete this project successfully.

IV
 INSTITUTION VISION & MISSION
Vision
❖ To emerge as a leader among the top institutions in the field of technical education.

Mission
❖ Produce smart technocrats with empirical knowledge who can surmount the global challenges.
❖ Create a diverse, fully-engaged, learner-centric campus environment to provide quality education
to the students.
❖ Maintain mutually beneficial partnerships with our alumni, industry and professional associations.

DEPARTMENT VISION, MISSION, PEO, PO & PSO

Vision
❖ To create globally recognized competent Mechanical engineers to work in multicultural
environment.
Mission
❖ To impart quality education in the field of mechanical engineering and to enhance their skills, to
pursue careers or enter into higher education in their area of interest.
❖ To establish a learner-centric atmosphere along with state-of-the-art research facility.
❖ To make collaboration with industries, distinguished research institution and to become a centre
of excellence

PROGRAM EDUCATIONAL OBJECTIVES (PEOS)

The graduates of Mechanical Engineering will be able to
❖ PEO1: Graduates of the program will accommodate insightful information of engineering
principles necessary for the applications of engineering.
❖ PEO2: Graduates of the program will acquire knowledge of recent trends in technology and solve
problem in industry.
❖ PEO3: Graduates of the program will have practical experience and interpersonal skills to work
both in local and international environments.
❖ PEO4: Graduates of the program will possess creative professionalism, understand their ethical
responsibility and committed towards society

v
 PROGRAM OUTCOMES

The following are the Program Outcomes of Engineering Graduates: Engineering

Graduates will be able to:

1. Engineering knowledge: Apply the knowledge of mathematics, science, engineering

fundamentals, and an engineering specialization to the solution of complex engineering problems.
2. Problem analysis: Identify, formulate, review research literature, and analyze complex
engineering problems reaching substantiated conclusions using first principles of mathematics,
natural sciences, and engineering sciences.
3. Design/development of solutions: Design solutions for complex engineering problems and design
system components or processes that meet the specified needs with appropriate consideration for
the public health and safety, and the cultural, societal, and environmental considerations.
4. Conduct investigations of complex problems: Use research-based knowledge and research
methods including design of experiments, analysis and interpretation of data, and synthesis of the
information to provide valid conclusions.
5. Modern tool usage: Create, select, and apply appropriate techniques, resources, and modern
engineering and IT tools including prediction and modeling to complex engineering activities with
an understanding of the limitations.
6. The engineer and society: Apply reasoning informed by the contextual knowledge to assess
societal, health, safety, legal and cultural issues and the consequent responsibilities relevant to the
professional engineering practice.
7. Environment and sustainability: Understand the impact of the professional engineering
solutions in societal and environmental contexts, and demonstrate the knowledge of, and need for
sustainable development.
8. Ethics: Apply ethical principles and commit to professional ethics and responsibilities and norms
of the engineering practice.
9. Individual and team work: Function effectively as an individual, and as a member or leader in
diverse teams, and in multidisciplinary settings.
10. Communication: Communicate effectively on complex engineering activities with the
engineering community and with society at large, such as, being able to comprehend and write
effective reports and design documentation, make effective presentations, and give and receive
clear instructions.
11. Project management and finance: Demonstrate knowledge and understanding of the engineering
and management principles and apply these to one’s own work, as a member and leader in a team,
to manage projects and in multidisciplinary environments.
12. Life-long learning: Recognize the need for, and have the preparation and ability to engage in
independent and life-long learning in the broadest context of technological change

vi
 PROGRAM SPECIFIC OUTCOMES (PSOs)

The following are the Program Specific Outcomes of Engineering Graduates:

The students will demonstrate the abilities
1. Real world application: To comprehend, analyze, design and develop innovative products and
provide solutions for the real-life problems.
2. Multi-disciplinary areas: To work collaboratively on multi-disciplinary areas and make quality
projects.
3. Research oriented innovative ideas and methods: To adopt modern tools, mathematical,
scientific and engineering fundamentals required to solve industrial and societal problems.

MAPPING OF PO & PSO WITH THE PROJECT OUTCOME

BLOOMS
Cos COURSE STATEMEN T PO 1 P0 2 PO 3 PO 4 PO 5 PO 6 PO 7 PO 8 P0 9 PO 10 PO 11 PO 12 PS O1 PS O2 PS O3
LEV EL
Formulate a real world problem,
identify the requirement and
1 develop the design K3 3 3 3 3 3 3 3 3 3 3 3
solutions.

Identify technical ideas,

2 K3 3 3 3 3 3 3 3 3 3 3 3
strategies and methodologies

Utilize the new tools, algorithms,

3 techniques that contribute to K4 3 3 3 3 3 3 3 3 3 3 3 3 3 3
obtain the solution of the project

Test and validate through

conformance of the developed
4 prototype and analysis the cost- K4 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3
effectiveness.

Prepare report and present oral

5 K4 3 3 3 3 3 3 3
demonstration

Average 3 3 3 3 3 3 3 3 3 3 3 3 3 3 3

vii
CHAPTER TABLE OF CONTENTS PAGE
NO NO

ABSTRACT VIII

LIST OF FIGURES XII

LIST OF TABLES XIII

LIST OF SYMBOLS XIV

1 Introduction 1

1.1 Background Of Project 1

1.2 Objective Of The Project 1

1.3 Scope And Limitations 2

1.4 Significance Of The Study 3

2 Literature Review 4

3 Company Overview Of Jbt Foams Pvt Ltd 8

3.1 Founding And History Of Jbt Pvt Ltd 8

3.2 Manufacturing Process At Jbt Foams Pvt Ltd 8

3.3 Product Portfolio And Offerings 9

4 Methodology 11

4.1 Research Design 11

4.2 Data Collection Methods 12

4.3 Data Analysis Procedures 13

ix
 Detailed Study Of The Current State Of The
5 15
Company

5.1 Introduction 15

5.2 Identifying Bottlenecks And Wastes 16

5.3 Market Projections And Industry Trends 18

5.4 The Lean Lab 18

6 Overview Of The Lean Laboratory App 19

6.1 Introduction 19

6.2 Design Of The Lean Laboratory App 19

6.3 Features Of The Lean Laboratory App 19

6.4 Functionality Of The Lean Laboratory App 21

6.5 Methodology 22

6.6 Value Stream Mapping (Vsm) 22

6.7 Data Collection And Analysis 22

7 Implementation Of Lean Methodologies 23

7.1 Streamlined Order Handling 23

7.2 Improved Inventory Management 23

7.3 Optimized Material Storage 24

7.4 Implementation Of Access Control 24

7.5 Batch Production With Kanban System 25

x
 7.6 Real-Time Process Monitoring 26

7.7 Data-Driven Decision Making 26

7.8 Efficient Product Flow 27

7.9 Improved Shipping Processes 28

8 Value Stream Analysis 28

8.1 Vision For Future State 28

8.2 Technology Integration 28

8.3 Employee Empowerment 29

8.4 Environmental Sustainability 29

8.5 Lean Innovation 30

8.6 Performance Monitoring 30

9 Result And Discussion 33

10 Conclusion 38

Appendices 39

Appendix 1 39

Appendix 2 40

Appendix 3 41

Appendix 4 42

References 43

xi
 LIST OF FIGURE

FIGURE TITLE PAGE

NO. NO

3.1 Drone View of the Industry 9

5.1 Current State VSM 17

6.1 Overview of Lean Laboratory 20

8.1. Future State VSM 29

xii
 LIST OF TABLES

TABLE TITLE PAGE

NO. NO
4.1 Data Collection 13

5.2 Identifying the Bottlenecks and Waste 16

8.1 Comparison of Current State vs. Future State 31

9.1 Assessment of Manufacturing Process 33

9.2 Observation of Gathering Environmental Impacts 34

9.3 Observation of Optimized Time Using Automation 36

xiii
 LIST OF SYMBOLS
kWh Unit of energy

kg Unit of mass

CO2 Chemical compound

µg/m³ Unit of particulate matter concentration

dB Unit of sound intensity

mins Unit of time

hrs Unit of time

m Unit of length

cm Unit of length

% Unit of proportion

D Unit of foam density

LD Foam type

MD Foam type

HD Foam type

OEE Metric for equipment performance

pH Measure of acidity/basicity

ACM Automation and Cellular Manufacturing

LCMS Lean Manufacturing Control System

xiv
 ABSTRACT
This project report focuses on implementing lean methodologies in the
mattress manufacturing industry to improve efficiency, reduce waste, and enhance
competitiveness. The report explores various aspects of lean implementation,
including process optimization, inventory management, quality control, and
environmental impact assessment. Through observational techniques and data
logging methods, areas for enhancement were identified, leading to targeted
interventions and adopting sustainable practices. Key findings include inventory
mismanagement, manual errors, and inefficient quality control procedures
addressed through process optimization and automation. Environmental analysis
revealed excessive resource consumption and waste generation, highlighting the
importance of sustainable manufacturing practices. The report also discusses the
results of process optimization efforts, including improved cycle times, reduced
defect rates, and enhanced overall productivity. By implementing lean
methodologies and embracing sustainability, companies can achieve long-term
success while minimizing environmental impact.

Keywords: Lean methodologies, mattress manufacturing, efficiency, waste

reduction, process optimization, inventory management, quality control,
sustainability

ix
 CHAPTER 1
INTRODUCTION
1.1 Background of the Project
The mattress manufacturing industry in India has witnessed remarkable
growth in recent years, fueled by factors such as rising consumer demand, increased
awareness of the importance of quality sleep, and the expansion of the hospitality
sector. With this growth comes the need for manufacturers to optimize their
processes, reduce waste, and enhance efficiency to stay competitive. This project
aims to address these challenges by implementing lean methodologies in a mattress
manufacturing company based in India.
Traditionally, mattress manufacturing has been a labor-intensive process with
multiple stages, including material preparation, cutting, assembly, quality control,
and packaging. However, inefficiencies in these processes, such as bottlenecks,
overproduction, and defects, can lead to increased costs and decreased customer
satisfaction. By adopting lean principles, the company seeks to streamline
operations, eliminate waste, and improve overall productivity.

1.2. Objectives of the Project

The primary objective of this project is to implement lean methodologies in
the mattress manufacturing company to achieve the following specific goals:
Increase operational efficiency: The company aims to streamline operations and
improve overall efficiency by identifying and eliminating waste in the production
process.
• Enhance product quality: By implementing lean principles such as
continuous improvement and standardized work, the company seeks to
enhance the quality of its mattresses and reduce defects.

1
 • Reduce lead times: The company aims to reduce lead times and improve
responsiveness to customer demand by optimizing production processes and
eliminating non-value-added activities.
• Improve resource utilization: Lean methodologies will optimize raw
materials, labor, and equipment, leading to cost savings and improved
profitability.
• Foster a culture of continuous improvement: By involving employees in
the lean implementation process and encouraging feedback and suggestions,
the company aims to create a culture of continuous improvement and
innovation.

1.3. Scope and Limitations

The main objective of the project is to optimize the mattress manufacturing
process by implementing lean methodologies in various critical areas, including
material preparation, cutting, assembly, quality control, and packaging. To achieve
this, the project team will comprehensively analyze each process to identify
inefficiencies, redundancies, and bottlenecks that hinder performance and propose
solutions to address them. The team will also work on improving the overall flow of
the manufacturing process to ensure maximum efficiency and productivity.
However, it's essential to note that implementing lean methodologies may
require significant changes in the company's existing processes and culture, which
could be met with employee resistance. Therefore, the project team will work closely
with management to ensure that the changes are communicated effectively to the
employees and that their concerns and feedback are heard and addressed.
In addition to the internal challenges, external factors such as market
dynamics and regulatory requirements may influence the project's outcomes, which
must be considered during the implementation phase. For example, changes in
2
customer demand or new regulations regarding material safety may require
modifications in the manufacturing process, which could impact the project's
timeline and budget.
Therefore, the project team will work diligently to ensure that all aspects of
the project are thoroughly analysed and planned to mitigate potential risks and
ensure a successful outcome.

1.4. Significance of the Study

This study is essential to the mattress manufacturing industry in India and
beyond. The company can enhance its competitiveness, improve product quality, and
reduce costs by implementing lean methodologies. Furthermore, the findings of this
study can serve as a valuable reference for other companies in the manufacturing
sector looking to adopt lean principles to improve their operations.
Overall, this project aims to contribute to the body of knowledge on lean
manufacturing and provide practical insights into its implementation in the mattress
manufacturing industry. By addressing inefficiencies and optimizing processes, the
company can position itself for sustainable growth and success in the dynamic
market landscape.

3
 CHAPTER 2
LITERATURE REVIEW

2.1. The Framework of Implementing Lean Manufacturing in the Indian

Textile Industry

Authors: M. Mohan Prasad, J.M. Dhiyaneswari, J. Ridzwanul Jamaan, S.

Mythreyan, and S.M. Sutharsan [1]

A group of researchers has developed a comprehensive framework for

implementing lean manufacturing in the Indian textile industry. Their framework
enhances the production process and improves product quality while increasing
customer satisfaction. The researchers have outlined the many potential benefits that
a diligent researcher has created and an all-encompassing framework tailored
explicitly for implementing lean manufacturing in the Indian textile industry. This
framework aims to optimize the production process, enhance product quality, and
boost customer satisfaction. The researchers have highlighted many advantages that
a lean manufacturing approach can offer the industry, such as shortening production
lead times, simplifying the supply chain, and augmenting production process
efficiency.

Nevertheless, the researchers have also acknowledged some potential

obstacles that may arise when trying to apply lean principles in the Indian textile
industry. These challenges include resistance to change due to cultural differences,
insufficient support from management, and inadequate employee training. To ensure
the successful implementation of a lean manufacturing approach in the Indian textile
industry, the researchers have offered practical recommendations for overcoming
these challenges. A lean manufacturing approach can be offered to the industry.

4
These benefits include but are not limited to, reducing production lead times,
streamlining the supply chain, and improving the overall efficiency of the production
process.

However, the researchers have also identified several challenges that may arise
when implementing lean principles in the Indian textile industry. These challenges
include cultural resistance to change, a lack of management support, and inadequate
employee training. The researchers have provided practical advice on overcoming
these challenges and successfully implementing a lean manufacturing approach in
the Indian textile industry.

With their detailed framework and practical advice, the researchers have provided
a valuable resource for companies in the Indian textile industry who are looking to
enhance their manufacturing processes and improve their products. By following the
guidelines outlined in this framework, companies can not only overcome any
challenges that may arise but also take advantage of the many benefits of lean
manufacturing.

2.2. Implementing Lean Principles in Furniture and Household Appliances

Renting

Authors: Yash Sand, Girish, and Devidas Thakar [2]

They conducted a case study on a piece of furniture and a household. A

furniture and appliances renting company underwent a comprehensive case study to
explore the areas where lean principles could be implemented to enhance overall
efficiency and reduce waste. The study primarily focused on the sofa manufacturing
process and aimed to provide practical insights into implementing lean principles in
furniture manufacturing. The researchers conducted an in-depth analysis of the

5
existing manufacturing process and identified several areas that could be optimized
by reducing waste, improving quality, and streamlining operations.

The study revealed that implementing lean principles and specific measures,
such as standardizing processes, reducing lead times, and minimizing defects, could
result in significant expense reductions, increased efficiency, and improved
performance. The study's authors highlighted how implementing these lean
principles could not only enhance the overall performance of the manufacturing
process but also result in higher customer satisfaction due to improved quality and
faster delivery times.

Overall, the study provided valuable insights into the practical implementation of
lean principles in furniture manufacturing and demonstrated how these principles can
positively impact the business's financial performance, efficiency, and customer
satisfaction. Appliances renting company's operations to identify areas where lean
principles could be applied to enhance efficiency and reduce waste. The study
specifically focused on the sofa manufacturing process and provided valuable
insights into practical ways of implementing lean principles in the furniture
manufacturing process. The authors highlighted how implementing lean principles
and specific measures can result in notable expense reductions, increased efficiency,
and improved performance and Customer satisfaction.

2.3. Application of Lean Principles in a Saudi Arabian Factory

Authors: Ateekh Ur Rehman, Yusuf S. Usmani, Usama Umer, and Mohammed

Alkahtani

A case study conducted by a group of researchers delved into implementing lean

principles to enhance manufacturing productivity in a factory in Saudi Arabia. The
study found that adopting lean principles resulted in a myriad of benefits, including
6
a reduction in production lead times, an improvement in product quality, and an
increase in customer satisfaction. However, the study's authors also highlighted the
common challenges manufacturers face when implementing a lean approach in such
a setting. These obstacles range from cultural resistance to change, inadequate
management support, and insufficient training. The authors also provided practical
advice on overcoming these challenges and successfully adopting a lean approach in
a Saudi Arabian factory.

The case study ultimately demonstrated the effectiveness of implementing a lean

approach in reducing waste and improving factory productivity while highlighting
the potential challenges that must be addressed to achieve such results.

7
 CHAPTER 3
COMPANY OVERVIEW: JBT FOAMS PVT LTD

3.1 Founding and History of JBT Foams Pvt Ltd

JBT Foams Pvt Ltd was established in the thriving industrial city of Karur,
Tamil Nadu. The company began with a small team and limited resources, but it
quickly gained traction in the Polyurethane foam manufacturing sector. Over the
years, through strategic planning and dedication, JBT Foams Pvt Ltd has
experienced steady growth, expanding its operations and client base.
The company's vision is to become a leading provider of high-quality
polyurethane foam products that cater to diverse industries and consumer needs. This
vision is complemented by the company's mission to continually innovate, deliver
exceptional value to customers, and uphold the highest standards of quality and
service. At the helm of JBT Foams Pvt Ltd is its visionary Managing Director,
Srimathi J. Thenmozhi. Her entrepreneurial spirit and leadership have been
instrumental in guiding the company's success. She is supported by a dynamic team
of professionals, including the Operation Head, Shri K. Jayabal, and the Marketing
Head, Shri N. Bathresh. The company's organizational structure is designed to foster
collaboration, innovation, and excellence, focusing on ensuring customer
satisfaction.

3.2 Manufacturing Processes at JBT Foams Pvt Ltd

JBT Foams Pvt Ltd takes immense pride in its state-of-the-art production
facilities, fully equipped with advanced machinery and cutting-edge technology. The
five-acre manufacturing plant is designed to house dedicated areas for every stage
of the production process, including material preparation, cutting, assembly, quality
control, and packing operations. Our production layout is carefully crafted to ensure
8
optimal workflow and efficiency, guaranteeing seamless operations from the intake
of raw materials to the output of finished products.
Our production facility boasts a range of cutting-edge equipment and
machinery, including foam mixing machines, cutting machines, assembly lines, and
quality testing equipment. Our skilled technicians operate these machines and
meticulously maintain them to ensure precision, consistency, and product excellence
at every production stage. Our foam mixing machines use advanced technology to
create foam with consistent density, while our cutting machines ensure precise
cutting of foam sheets to exact measurements. In addition, our assembly lines are
fully automated to ensure efficient and accurate product assembly. At the same time,
our quality testing equipment is designed to detect and rectify any product defects.
At JBT Foams Pvt Ltd, we take great care to ensure that our equipment and
machinery are regularly calibrated and maintained to operate at their optimum level.
This, coupled with our skilled workforce, ensures that we deliver high-quality
products that meet the exacting standards of our clients.

FIGURE 3.1: DRONE VIEW OF THE INDUSTRY

3.3 Product Portfolio and Offerings
Range of Polyurethane Foam Products: JBT Foams Pvt Ltd offers a
comprehensive range of Polyurethane foam products tailored to meet the diverse
9
needs of its customers. From High Resiliency (HR) foam renowned for its elasticity
and durability to Fire Retardant (FR) foam designed for safety compliance, the
company's product portfolio encompasses a variety of foam types, densities, and
specifications.
• Specifications and Applications: Each JBT Foams Pvt Ltd portfolio product
is engineered to meet stringent quality standards and performance
requirements. Whether used in mattresses, furniture, automotive interiors, or
other applications, the company's Polyurethane foam products deliver
superior comfort, support, and durability.
• Unique Selling Propositions and Value Propositions: What sets JBT Foams
Pvt Ltd apart from its competitors is its unwavering commitment to
innovation, quality, and customer satisfaction. The company's products are
distinguished by their exceptional resilience, fire safety features, and
ergonomic design, making them the preferred choice for industries and
consumers. Additionally, JBT Foams Pvt Ltd's value proposition lies in its
ability to offer customized solutions, timely delivery, and responsive customer
service, ensuring a seamless experience for clients from start to finish.
In summary, JBT Foams Pvt Ltd stands as a beacon of excellence in the
Polyurethane foam manufacturing industry, driven by a compelling vision, robust
manufacturing processes, and a diverse portfolio of high-quality products. With a
strong leadership team and a dedication to innovation and customer satisfaction, the
company is well-positioned to continue its growth and success in the future.

10
 CHAPTER 4
METHODOLOGY
4.1. Research Design
In this section, the research design adopted for the study is elucidated, including
the approach to data collection, research framework, and sampling techniques.
• Approach to Data Collection: The approach involves determining the methods
and techniques for gathering information pertinent to the research objectives.
This study employed a mixed-method approach combining quantitative and
qualitative data collection techniques to understand the subject matter
comprehensively. This approach allows for data triangulation, enhancing the
findings' validity and reliability.
• Research Framework: The research framework outlines the conceptual
underpinnings and theoretical foundations guiding the study. It provides a
structured approach to organizing and analyzing data within the context of the
research objectives. For this study, the research framework is based on lean
manufacturing principles, quality assurance practices, and market analysis,
providing a holistic perspective on the manufacturing processes at JBT Foams
Pvt Ltd.
• Sampling Techniques: Sampling techniques are crucial for selecting
representative samples from the population under study. This research employed
a purposive sampling technique to select participants and data sources that best
align with the research objectives. The sample size was determined based on
accessibility, feasibility, and relevance to the study's objectives. By employing
purposive sampling, the study aimed to ensure the inclusion of diverse
perspectives and experiences relevant to the research context.

11
4.2. Data Collection Methods
This section delineates the various methods for collecting data, including primary
and secondary data collection, and the sources and instruments utilized.
• Primary Data Collection: Primary data collection is vital in conducting
research, as it involves gathering firsthand information directly from the source.
This study collected primary data through various methods such as structured
interviews, surveys, and direct observations at JBT Foams Pvt Ltd's
manufacturing facilities. These methods enabled the researchers to collect real-
time data on production processes, quality assurance practices, and employee
perspectives, which helped them gain a more comprehensive understanding of
the organization's operations and performance.
• Secondary Data Collection: Secondary data collection is a crucial research
method that involves gathering information from existing sources such as
research articles, industry reports, and company documents. In the context of a
particular study, secondary data sources can provide valuable insights into the
research topic and help to contextualize primary data findings. This study
utilized various secondary data sources, including academic journals, industry
publications, government reports, and company records. The study aimed to
comprehensively analyze the research topic and draw meaningful conclusions
by synthesizing information from these sources. The use of secondary data
sources can be beneficial in providing a broader perspective on the research topic
and identifying key trends and patterns that may not be immediately apparent
from primary data alone. So, secondary data collection is a critical component
of any research study that can help to enhance the validity and reliability of
research findings.

12
• Data Sources and Instruments:
Data Collection Method Description
Conducted with key personnel,
including management, production
staff, and quality control inspectors,
Structured Interviews
to gather insights into manufacturing
processes, challenges, and
improvement opportunities.
They were administered to employees
at various levels to assess their
Surveys perceptions, attitudes, and satisfaction
with work processes and
organizational practices.
This was undertaken during site visits
to JBT Foams Pvt Ltd's
manufacturing facilities to observe
Direct Observations
production processes, equipment
utilization, and quality control
measures.

Table 4.1: Data Collection Methods

4.3. Data Analysis Procedures
This section elucidates the procedures and techniques for analyzing the
collected data, encompassing quantitative analysis techniques, qualitative analysis
methods, statistical tools and software.
• Quantitative Analysis Techniques: Quantitative analysis involves the
statistical examination of numerical data to identify patterns, trends, and
relationships. For this study, quantitative analysis techniques such as descriptive
statistics, correlation analysis, and regression analysis were utilized to analyze
quantitative data obtained from surveys and structured interviews. These
techniques facilitated the identification of significant variables and assessing
their impact on manufacturing processes and performance metrics.

13
• Qualitative Analysis Methods: Qualitative analysis involves systematically
interpreting textual or non-numerical data to extract meaning and generate
insights. This study used qualitative analysis methods such as thematic analysis,
content analysis, and constant comparative analysis to analyze qualitative data
obtained from open-ended survey responses and direct observations. These
methods allowed for identifying key themes, patterns, and narratives within the
data, providing rich and nuanced insights into the research topic.

14
 CHAPTER 5
DETAILED STUDY OF THE CURRENT STATE OF THE COMPANY

5.1 Introduction
India's mattress manufacturing industry is experiencing a substantial growth
trend, which can be attributed to various factors. One of the key drivers of this
growth is the increased spending power of consumers, who are now more willing
to invest in high-quality products that promote overall health and well-being. Also,
heightened awareness about the importance of mattresses for sleep quality has
contributed to this growth trend, as consumers become more educated about the
benefits of using the correct type of mattress for their needs.
Another significant factor contributing to the growth of the mattress
manufacturing industry in India is the expansion of the hospitality sector. With more
hotels and resorts opening up in India, there has been an increased demand for high-
quality mattresses to provide guests with a comfortable and restful sleep experience.
In light of this growth trend, this chapter aims to comprehensively analyze the
current state of JBT Foams Pvt Ltd, one of the leading players in the Indian mattress
manufacturing industry. Through this analysis, we aim to identify areas of
improvement, bottlenecks, and opportunities for growth, which can help JBT
Foams Pvt Ltd stay ahead of the competition and continue to thrive in this dynamic
and evolving market.

5.2 Identifying Bottlenecks and Waste

Table 2 presents observations regarding bottlenecks and waste identified
across different JBT Foams Pvt Ltd processes. These observations are crucial for
understanding areas that require optimization and improvement to enhance
efficiency and productivity.
15

Task Description
Observe Weaving Process
Analyze Cutting Process
Review Stitching Process
Examine Finishing Process
Inspect Quality Control
Assess Packaging Process
Investigate Inventory Flow
Examine Maintenance Issues
Evaluate Employee
Workflow
Identifying Bottlenecks and
Waste
Gathering data on
environmental impact
Organizing the Lean
Innovation Workshop
Prioritizing innovative
solutions
Implementing Lean
innovations
Monitoring KPIs
Gathering employee
feedback
Developing a sustainability
plan
Defining KPIs for
sustainability
Creating a roadmap for
continuous improvement
Table 5.1: Identifying Bottlenecks and Waste
Observations (Bottlenecks
and Waste)
The weaving process appears
efficient and well-organized
The cutting process is
accurate and timely
The stitching process shows
consistency in quality
The finishing process results
in smooth surfaces
Quality control procedures
are in place
The packaging process meets
safety standards
Inventory flow appears well-
managed
Some equipment requires
minor repairs
Employee workflow seems
systematic
Bottlenecks are causing
minor delays
Data on environmental
impact is limited
Workshop participants are
engaged
Several innovative ideas
have been generated
Lean innovations are being
implemented
Key Performance Indicators
(KPIs) are tracked
Employees are providing
valuable feedback
A sustainability plan outlines
clear objectives
Key sustainability metrics
are identified
The roadmap outlines
actionable steps
16
Proposed Solutions
Consider periodic equipment
maintenance
Explore automation for higher
efficiency
Cross-train employees for
flexibility
Implement quality control
checks
Enhance employee training
programs
Optimize packaging material
usage
Implement a digital inventory
system
Schedule regular equipment
maintenance
Encourage employee feedback
for improvement
Analyze and address
bottleneck causes
Conduct an environmental
audit
Document workshop outcomes
and action items
Establish a priority matrix for
solutions
Monitor implementation
progress closely
Establish KPI targets for
continuous improvement
Create a feedback loop for
employee suggestions
Collaborate with experts for
sustainable practices
Regularly review and update
sustainability KPIs
Share the roadmap with all
stakeholders
FIGURE 5.1: CURRENT STATE VSM

17
5.3 Market Projections and Industry Trends
According to recent projections, the mattress manufacturing industry in
India is expected to experience a remarkable growth rate of 7.7% from 2024 to
2032. The driving force behind this impressive growth is the increasing demand
from consumers, coupled with the emergence of innovative Indian startups that
contribute significantly to the market's expansion. This represents a promising
development for the industry, poised to meet the needs of a rapidly growing
population looking for comfortable and affordable bedding options.

5.4 The Lean Lab Project

The Lean Lab project aims to implement lean principles in the mattress
manufacturing industry to enhance efficiency, reduce waste, and drive continuous
improvement. Various strategies and initiatives have been identified, including
implementing lean innovations, monitoring KPIs, gathering employee feedback,
and developing a sustainability plan.

18
 CHAPTER 6
OVERVIEW OF THE LEAN LABORATORY APP

6.1 Introduction
The Lean Laboratory app represents a significant advancement in process
optimization and efficiency enhancement within manufacturing industries.
Developed using the MIT App Inventor platform, this innovative application
integrates lean principles and tools from extensive industry observations and
implementations. This chapter provides an overview of the Lean Laboratory app,
highlighting its design, features, and functionality.

6.2 Design of the Lean Laboratory App

The Lean Laboratory app is meticulously crafted to provide an exceptional
user experience. The app's interface is thoughtfully designed, with user-friendliness
and efficiency at the forefront of its development. The intuitive layout of the
application ensures that users of all skill levels can easily navigate the app. The
app's design is clean, minimalistic, and organized, facilitating seamless interaction
and ensuring that users can access the app's features effortlessly. The app's features
are strategically placed, making them easily accessible and improving the overall
user experience. The Lean Laboratory app's design and layout are a testament to
the developer's commitment to providing an exceptional user experience.

6.3 Features of the Lean Laboratory App

The Lean Laboratory app offers a range of features to enhance process
optimization and decision-making within manufacturing industries. These features
include:

19
6.3.1 Theoretical Analysis
The app enables users to input relevant process data and parameters, allowing
it to conduct comprehensive theoretical analyses. Using lean implementation tools,
the app generates theoretically optimized values for crucial process metrics,
providing insights into potential improvements.
6.3.2 Real-Time Calculations
Users can input real-time data from ongoing processes, allowing the app to
calculate and compare performance metrics with theoretical benchmarks. This real-
time functionality enables users to assess process efficiency on the fly and identify
areas for improvement.
6.3.3 Lean Tools Integration
The app integrates lean tools and methodologies, including Value Stream
Mapping (VSM), 5S, Kanban, and Continuous Improvement (Kaizen). Users can
leverage these tools to streamline processes, reduce waste, and drive continuous
organizational improvement.
6.3.4 Comparison and Decision-Making
A standout feature of the app is its ability to compare current process states
with theoretically optimized states. The app empowers users to make informed
decisions and prioritize optimization strategies by providing clear visualizations
and data-driven insights.
6.3.5 Streamlined Process
Designed for simplicity and efficiency, the Lean Laboratory app streamlines
conducting lean analyses and implementing optimization strategies. Its user-
friendly interface ensures a seamless user experience, enabling users to focus on
driving tangible improvements in their organizations.

20
6.4 Functionality of the Lean Laboratory App
The Lean Laboratory app's functionality encompasses theoretical analysis,
real-time calculations, integration of lean tools, comparison and decision-making,
and streamlined process execution. Users can leverage these functionalities to
identify opportunities for improvement, optimize processes, and drive
organizational excellence.

FIGURE 6.1: OVERVIEW OF LEAN LABORATORY (A, B, C, D)

The figure visually represents the Lean Laboratory app, highlighting its key features
and functionalities.

21
6.5 Methodology
The Lean Laboratory app has been instrumental in driving process
optimization methodologies within manufacturing industries. Various approaches,
including automation, cellular manufacturing, and lean tools integration, have been
employed to enhance process efficiency and productivity. The app facilitates real-
time analysis, comparison, and decision-making, providing a clear roadmap for
driving continuous improvement initiatives.

6.6 Value Stream Mapping (VSM)

Value Stream Mapping (VSM) has been utilized to analyze and improve the
flow of materials and information throughout the manufacturing process. This
methodology involves mapping out the current state of the production process,
identifying bottlenecks, waste, and inefficiencies, and developing a future state map
to outline ideal process optimization strategies.

6.7 Data Collection and Analysis

Data collection and analysis play a crucial role in driving continuous
improvement efforts. Using manual observation, automated sensors, and data
logging systems, observational data from the manufacturing environment is
gathered and analyzed using statistical techniques and software. The Lean
Laboratory app is a central platform for collecting, analyzing, and visualizing this
data, enabling real-time performance monitoring and data-driven decision-making.

22
 CHAPTER 7

IMPLEMENTATION OF LEAN METHODOLOGIES

7.1 Streamlined Order Handling

In this section, we will dive into the changes that were implemented to optimize the
order-handling process. Before the changes, when we needed to place orders for raw
materials, the requests used to go through intermediaries, which often resulted in
communication delays and longer lead times. Our new process involves placing
orders directly with the raw material handler. This has resulted in a more efficient
flow of materials into the production process, thereby reducing waiting times and
lead times. The new process has also allowed us to monitor the progress of the orders
better and ensure timely delivery of the raw materials, dramatically improving our
production capacity and customer satisfaction.

7.2 Improved Inventory Management

Efficient and smooth operations are essential for any business to succeed, and proper
inventory management plays a crucial role in achieving this. Accurate and up-to-
date records of your stocks are vital for optimal inventory management. This is why
our organization has implemented a new approach to inventory management, which
is proactive and ensures that our inventory records are always accurate and up to
date. We now diligently take stock every 15 days without fail, and our team uses
advanced software to track and monitor stock levels in real time, which enables us
to identify potential issues or discrepancies before they become problems.
This proactive approach to inventory management has numerous benefits. Firstly, it
enables better control over inventory levels, preventing situations with too much or
too little inventory, which can lead to lost sales or unnecessary costs. Additionally,
23
it helps us identify slow-moving items or items that are not selling as well as we
expected. This allows us to take corrective action and optimize our inventory levels
accordingly.
Overall, this proactive approach has significantly enhanced our efficiency and
productivity. It has helped us minimize waste, reduce costs, and improve customer
satisfaction. We are confident that this approach will continue to be a critical factor
in our success as we move forward.

7.3 Optimized Material Storage

Ensuring efficient management of material storage is essential for businesses

to optimize space utilization and minimize waste. Implementing efficient material
storage practices can help companies maintain optimal space utilization while
reducing the risks of stockouts or overstock situations. By conducting regular
inventory checks every 15 days, businesses can keep their inventory records up-to-
date and accurate, which can help prevent stockouts or overstock scenarios that can
result in unnecessary waste and inefficiencies in material handling.

This improvement in inventory control can significantly impact businesses,

providing greater visibility into their inventory levels, reducing waste, and
improving operational efficiency in material handling. With a well-managed
material storage system, businesses can use their space effectively and minimize
waste, increasing profitability and sustainability.

7.4 Implementation of Access Control

Access control measures have been implemented to ensure the security and
accountability of the Material Control Center. These measures limit center access to
authorized personnel, minimizing the risk of unauthorized access or tampering with
24
materials that could compromise process integrity. Implementing these measures has
resulted in a safer environment for employees and materials while enhancing
reliability and trustworthiness. The measures include physical and digital access
controls, including key cards, biometric scans, and complex passwords.
Additionally, a comprehensive monitoring system has been implemented to track
and record all access attempts, adding an extra layer of security and helping identify
potential security breaches.
Overall, the access control measures have significantly improved the security
and accountability of the Material Control Center, ensuring that materials are kept
safe and processes are carried out with integrity and reliability.

7.5 Batch Production with Kanban System

The implementation of the Kanban system has significantly changed our

production processes. With the transition to batch production and the use of visual
cues, we have been able to streamline our workflow and optimize our production
levels based on customer demand. This approach has resulted in a marked reduction
in inventory levels, minimized waste, and enhanced our ability to respond to
customer needs promptly and efficiently.
The Kanban system essentially involves using visual cues, such as cards or
boards, to signal the need to replenish materials or initiate production. By producing
in batches, we can achieve a higher efficiency level in our production processes, as
we can optimize our machinery and equipment for specific tasks. This, in turn,
results in improved quality control and reduced defects.
The benefits of this system are not limited to our internal operations. By
minimizing inventory levels, we can reduce our operating costs and improve our
cash flow. Furthermore, the improved responsiveness to customer needs has resulted

25
in higher customer satisfaction levels and increased customer loyalty. Overall, the
transition to batch production with the Kanban system has been a game changer for
our business, and we look forward to optimizing our processes as we advance.

7.6 Real-Time Process Monitoring

In today's fast-paced business environment, it is crucial to identify and address

inefficiencies in real time to stay ahead of the competition. Our Lean Laboratory
software application is designed to help you achieve this goal by providing accurate
and up-to-date information on your production processes.
One key feature of our software is its ability to record and calculate the time taken
during each stage of the production process. This data is then analyzed to provide
immediate feedback on performance, allowing you to make timely interventions and
adjustments as needed.
By Monitoring your processes in real-time, our software helps you optimize
efficiency and reduce waste throughout production. This saves you time and money
and ensures that you deliver high-quality products to your customers. With our Lean
Laboratory software, you can rest assured that you are making the most of your
resources and staying ahead of the competition.

7.7 Data-Driven Decision Making

As part of our Lean implementation strategy, we rely on data-driven decision-
making to continuously improve our processes and boost productivity. Our
supervisors receive regular updates on the analysis and monitoring of our operations,
enabling them to make informed decisions based on real-time data. By leveraging
the insights we gain from data, we can drive our business forward and achieve our
goals more efficiently and effectively.

26
7.8 Efficient Product Flow

A streamlined product flow is critical for any manufacturing or distribution process.

It helps to reduce bottlenecks and ensure maximum throughput. In this regard,
integrating withdrawn batches with the Products Kanban system is a great way to
ensure a smooth and seamless flow of products throughout the production and
distribution process. This synchronization ensures no delays in the supply chain,
enhancing process efficiency and maximizing throughput. Overall, this integration
helps to optimize the production process, reduce waste, and ensure timely delivery
of products to customers.

7.9 Improved Shipping Processes

Optimizing shipping processes in today's fast-paced business world is crucial

to ensure timely delivery and customer satisfaction. The Shipping Control Center
employs advanced techniques and technologies to effectively manage warehouse
operations and ship products to various outlets to achieve this goal. One critical
method that the center uses is the sequenced pull bar method, which involves
organizing inventory in a specific order to facilitate easy picking and packing.

By utilizing this method, the center can ensure that products are shipped most
efficiently, reducing transportation costs and overall turnaround time. In addition,
the Shipping Control Center employs real-time tracking and monitoring of
shipments, proactive communication with customers, and active risk management
to mitigate any unforeseen issues that may arise during the shipping process. The
center's focus on optimizing shipping processes is crucial to enhancing overall
customer satisfaction and maintaining a competitive edge in the marketplace.

27
 CHAPTER 8
VALUE STREAM ANALYSIS

8.1 Vision for Future State

As we contemplate the future of mattress manufacturing, we envision a
plethora of advancements that will significantly enhance the efficiency and quality
of the entire process. While the first stage of acquiring raw materials will remain
consistent, subsequent processes are expected to undergo significant
transformations.
We aim to integrate a state-of-the-art Lean Laboratory control center to
oversee and optimize every operation, from material processing to packaging. This
modern control center will employ cutting-edge technologies like automated
systems to monitor and optimize production processes in real-time, ensuring
seamless workflow and strict adherence to quality standards.
To further streamline the manufacturing process, we plan to adopt a digital
inventory management system to minimize waste and optimize resource utilization.
This sophisticated system will ensure that we have the right amount of raw
materials at the right time, thus preventing unnecessary stockpiling and reducing
the chances of shortages.
With this system, we can track every component of our products, from raw
materials to finished mattresses, ensuring complete traceability and accountability.
Our ultimate goal is to enhance efficiency, improve quality, and ensure
sustainability in all areas of mattress manufacturing. We are committed to
developing innovative solutions that meet our customers' needs while maintaining
the highest quality and safety standards.

28
FIGURE 8.1: FUTURE STATE VSM

29
8.2 Technology Integration
In our discussion, we focus on integrating advanced technologies into the
value stream that will be adopted in the future. Specifically, we are considering
implementing a digital inventory management system to revolutionize the
traditional inventory control process significantly. Using this system, we can track
the inventory status in real time, which will help us identify stock discrepancies and
take corrective measures promptly.
Additionally, we plan to schedule routine equipment maintenance using
predictive maintenance algorithms. This technology will enable us to predict the
maintenance requirements of equipment in advance and schedule maintenance
accordingly. By doing so, we can ensure that the equipment is always in optimal
condition, which will help prevent downtime and delays in production.
Integrating these new technologies into our value stream will ensure that we
operate efficiently while reducing the risk of errors and delays that can negatively
impact our business operations.

8.3 Employee Empowerment

Employee empowerment will play a crucial role in the future state value
stream. A systematic workflow will be established to optimize task allocation and
improve productivity. Furthermore, employees will be encouraged to offer
suggestions for process improvement, fostering a culture of continuous
improvement and innovation within the organization.

8.4 Environmental Sustainability

Environmental sustainability will be prioritized in the future state value
stream. An environmental audit will be conducted to assess the company's impact
and identify areas for improvement. A sustainability plan will be developed,
30
outlining clear objectives and strategies for reducing environmental footprint and
promoting eco-friendly practices.

8.5 Lean Innovation

In the future, the value stream will rely heavily on lean innovation to drive
continuous improvement. This means businesses must generate new ideas and
solutions to enhance their processes. One way to achieve this is through Lean
Innovation Workshops, where teams can brainstorm and develop creative ideas that
can help improve the value stream. These ideas will then be evaluated based on
their potential impact and feasibility. The most promising ideas will be
systematically implemented to enhance process efficiency and quality. By
embracing lean innovation, businesses can continuously improve their operations
and stay ahead of the competition.

8.6 Performance Monitoring

Establishing a robust performance monitoring system is crucial to ensure a
value stream's long-term success. This system should include identifying and
tracking pertinent Key Performance Indicators (KPIs), allowing for a
comprehensive evaluation of process performance. Regular review of these KPIs
provides valuable insights that enable informed decision-making and continuous
improvement efforts.
The data collected through performance monitoring serves a vital role in
identifying areas for optimization within the value stream. Organizations can make
data-driven decisions to improve efficiencies and outcomes by highlighting
potential issues that require attention.
In particular, performance monitoring data can identify bottlenecks and areas
of low productivity, helping streamline processes and reduce waste. It can also help
31
to identify areas where additional resources may be needed, such as training or
equipment upgrades.
A robust performance monitoring system is essential for organizations looking
to optimize their value stream and achieve long-term success. By regularly
reviewing KPIs and making data-driven decisions, organizations can improve
efficiencies, reduce waste, and ultimately provide better outcomes for their
stakeholders.

Aspect Current State Future State

Manual inventory tracking;
Inventory Management
occasional discrepancies
Equipment Reactive maintenance;
Maintenance occasional downtime
Informal task allocation;
Employee Workflow
limited feedback loop
Limited awareness; no
Environmental Impact
sustainability plan
Ad-hoc improvement
Lean Innovation initiatives; minimal
innovation
Digital inventory
management; real-time
tracking
Predictive maintenance;
minimized downtime
Systematic workflow;
culture of continuous
improvement
Environmental audit;
sustainability plan
Lean Innovation
Workshops; systematic
implementation

Table 5: Comparison of Current State vs. Future State

32
 CHAPTER 9
RESULT AND DISCUSSION
9.1 Result
The results and discussions encompassing observational techniques and data
logging methods in the manufacturing environment have been analyzed thoroughly
to evaluate processes, pinpoint areas for enhancement, and assess environmental
impacts. Findings across various manufacturing stages revealed inventory
mismanagement, manual errors, and inefficient quality control procedures, leading
to delays, inconsistencies, and increased defect rates. Bottlenecks like manual
handling and reliance on visual inspections were identified, contributing to
inefficiencies and higher production costs.
The environmental analysis highlighted excessive resource consumption,
waste generation, and carbon emissions, emphasizing the need for sustainable
practices to mitigate environmental degradation. Product quality metrics and
production efficiency indicators were scrutinized to identify improvement areas,
while observations of optimized time using automation showcased enhanced
efficiency and productivity. Understanding different foam types, densities,
applications, and usage is crucial for selecting appropriate materials.
Overall Equipment Effectiveness (OEE) calculations provided comprehensive
insights into equipment utilization and quality levels, guiding improvements in
production processes. In conclusion, by implementing targeted interventions,
sustainable practices, and automation technologies, companies can optimize
operations, reduce costs, and contribute to long-term success while minimizing their
environmental impact.

33
 ASSESSMENT OF MANUFACTURING PROCESS

Process Key Metrics to Data Action

Step Observations
Description Assess Collected Required
Raw material
Maintain
Step Raw Material Raw material quality is
Daily usage supplier
1 Preparation quality consistent, with
relationships
no issues
Consistent
Monitor mixing
Step Mixing and Mixing mixing
Batch records equipment for
2 Blending efficiency efficiency, no
maintenance
variations
Consistent foam Monitor foam
Step Foam Foam density, Production
quality, no production for
3 Formation quality logs
defects any anomalies
Accurate Monitor cutting
Step Shaping and Cutting Production
cutting, minimalequipment for
4 Cutting precision logs
waste maintenance
Monitor the
Strong bonds,
Step Bonding Bonding bonding
Quality tests passing quality
5 Layers strength process for
tests
consistency
Continuously
High-quality
Step Covering and Upholstery train the
Quality tests upholstery meets
6 Upholstery quality upholstery
standards
team
Continuously
Low defect rate,
Step Quality train quality
Defect rate Inspection data meeting quality
7 Control control
standards
inspectors
Monitor
On-time
Step Packaging and On-time Delivery shipping
deliveries, no
8 Shipping delivery records logistics and
delays
carriers
Equipment Implement
Step Maintenance Equipment Maintenance uptime is high, preventive
9 and Cleaning uptime logs and minimal maintenance
breakdowns schedules

TABLE 9.1: OBSERVATION OF ASSESSMENT OF MANUFACTURING

PROCESS

34
 GATHERING DATA ON ENVIRONMENTAL IMPACTS
Parameter Average Observation (30 days) Notes/Comments
Energy Consumption Calculated based on production
5000 kWh
(Electricity) processes
Standard water usage for foam
Water Usage 100 liters
production
Estimated carbon emissions from
CO2 Emissions 10 kg CO2
energy consumption
Material Usage (Polyurethane Daily consumption of PU foam for
1000 kg
Foam) production
Material Usage (Other Daily consumption of other materials
500 kg
Materials) for production
Standard pH levels for industrial
Water Quality (pH Levels) 7
water discharge
Controlled particulate matter
Air Quality (Particulate Matter) 15 µg/m³
emissions
Noise Levels 15 dB Noise levels within permissible limits
Daily packaging waste from finished
Packaging Waste 100 kg
products
Estimated daily chemical usage in
Chemical Usage 5 liters
production
Product Recycling 10% Percentage of products recycled
Product Waste 3% Percentage of products wasted
Water Consumption (Cooling) 2000 liters Water used for cooling processes
Energy Usage (Lighting) 100 kWh Energy consumed for lighting
Daily packaging material used for
Material Packaging 200 kg
products
Product Quality (Defect Rate) 2% Percentage of defective products
Raw Material Sourcing (Within Percentage of raw materials sourced
80%
India) locally
Raw Material Sourcing Percentage of raw materials sourced
20%
(Imported) internationally
Percentage of packaging materials
Product Packaging (Recycled) 60%
made from recycled content
Product Packaging Percentage of biodegradable
10%
(Biodegradable) packaging materials used
Energy from Renewable Percentage of energy from renewable
15%
Sources sources
Employee Training Ongoing training for employees on
Regular training programs
(Environmental) environmental practices
Engaging with the local community
Community Engagement Regular community outreach
for environmental initiatives

TABLE 9.2: OBSERVATION OF GATHERING ENVIRONMENTAL

IMPACTS
35
 D-1 OP/D-1 D-2 OP/D-2 D-3 OP/D-3 D-4 OP/D-4 Avg.
Process
(min) (min) (min) (min) (min) (min) (min) (min) O/T
Material
6.75 4.73 6.85 4.8 6.65 4.66 6.7 4.69 4.72
Preparation
Cutting 9 6.3 9.1 6.37 8.9 6.23 9 6.3 6.3
Assembly 11.25 7.88 11.35 7.95 11.15 7.81 11.25 7.88 7.88
Quality Control 4.5 3.15 4.55 3.19 4.45 3.12 4.5 3.15 3.15
Packaging 6.75 4.73 6.85 4.8 6.65 4.66 6.7 4.69 4.72

(A)

D-1 OP/D-1 D-2 OP/D-2 D-3 OP/D-3 D-4 OP/D-4 Avg.

Process
(min) (min) (min) (min) (min) (min) (min) (min) O/T
Material
6.75 4.19 6.85 4.25 6.65 4.12 6.7 4.15 4.18
Preparation
Cutting 9 5.58 9.1 5.64 8.9 5.52 9 5.58 5.58
Assembly 11.25 6.98 11.35 7.04 11.15 6.91 11.25 6.98 6.98
Quality Control 4.5 2.79 4.55 2.82 4.45 2.76 4.5 2.79 2.79
Packaging 6.75 4.19 6.85 4.25 6.65 4.12 6.7 4.15 4.18

(B)

D-1 OP/D-1 D-2 OP/D-2 D-3 OP/D-3 D-4 OP/D-4 Avg.

Process
(min) (min) (min) (min) (min) (min) (min) (min) O/T
Material
6.75 4.39 6.85 4.45 6.65 4.32 6.7 4.36 4.38
Preparation
Cutting 9 5.85 9.1 5.92 8.9 5.79 9 5.85 5.85
Assembly 11.25 7.31 11.35 7.37 11.15 7.25 11.25 7.31 7.31
Quality Control 4.5 2.93 4.55 2.96 4.45 2.89 4.5 2.93 2.93
Packaging 6.75 4.39 6.85 4.45 6.65 4.32 6.7 4.36 4.38
(C)

TABLE 9.3: Observation of Optimized Time Using (a) Automation, (b) ACM,
(c) LCMS

36
 CHAPTER 10
CONCLUSION

In conclusion, the thorough assessment and analysis conducted in this study

have shed light on various aspects of the mattress industry's manufacturing process.
Critical areas for enhancement and optimization have been identified through
observational techniques, data logging methods, and environmental impact
assessments.
Observations across different manufacturing stages revealed challenges such
as inventory mismanagement, manual errors, inefficient quality control procedures,
and reliance on outdated processes. These shortcomings contribute to delays,
inconsistencies, and increased defect rates, ultimately impacting operations' overall
efficiency and cost-effectiveness.
Furthermore, the environmental analysis highlighted the industry's significant
resource consumption, waste generation, and carbon emissions. This emphasizes
the urgent need for sustainable practices and initiatives to mitigate environmental
degradation and promote responsible manufacturing.
By implementing targeted interventions, including automation technologies, lean
methodologies, and sustainable practices, companies operating in the mattress
manufacturing industry can optimize their operations, reduce costs, and contribute
to long-term success while minimizing their environmental footprint.
The assessment of the manufacturing process, coupled with the data gathered
on environmental impacts, provides a comprehensive understanding of the
industry's current state and areas for improvement. Through continuous monitoring,
analysis, and adaptation, companies can strive towards achieving operational
excellence, ensuring competitiveness, sustainability, and growth in the dynamic
manufacturing landscape.
37
 APPENDIX 1
ACCEPTANCE LETTER FROM CASE STUDY INDUSTRY

38
 APPENDIX 2
PROJECT SCHEDULE

Action Taken/
Name of the Data Collection & Implementation and
Phase Activity/Task
Phase Analysis Key Performance
Indicators (KPIs)
Assessment of Daily production Implemented process
Phase 1: Current Production efficiency,
manufacturing records, process flow optimization
State Analysis cost reduction
processes analysis measures
Identifying Time and motion Streamlined Improved production
Phase 1: Current
bottlenecks studies, waste workflows, reduced throughput, waste
State Analysis
and waste tracking waste generation reduction
Gathering data Implemented eco-
Emissions Environmental
Phase 1: Current on friendly practices,
monitoring, energy compliance, energy
State Analysis environmental reduced energy
consumption data savings
impact consumption
Phase 2: Lean Conducted
Organizing the Workshop agenda, Employee engagement,
Innovation successful workshop
workshop participant feedback innovation adoption
Workshop sessions
Phase 2: Lean Prioritizing Idea generation Identified and Innovation
Innovation innovative sessions, prioritized implementation rate,
Workshop solutions prioritization criteria innovative ideas impact on KPIs
Phase 3: Implementing Project progress Executed Lean
Process improvement,
Implementation Lean reports, performance innovations in
efficiency gains
and Testing innovations metrics production
Phase 3: KPI tracking Continuously
Monitoring KPI alignment,
Implementation dashboard, real-time monitored KPIs for
KPIs performance trends
and Testing data deviations
Phase 3: Gathering Addressed employee
Employee surveys, Employee satisfaction,
Implementation employee concerns, improved
feedback sessions productivity
and Testing feedback morale
Phase 4:
Developing a Sustainability Implemented
Sustainability Environmental impact
sustainability strategy sustainability
and Future reduction, compliance
plan documentation initiatives
Roadmap
Phase 4:
Defining KPIs Sustainability KPI Sustainability
Sustainability Established
for framework, baseline performance, goal
and Future sustainability KPIs
sustainability data achievement
Roadmap
Phase 4: Creating a
Roadmap Implemented
Sustainability roadmap for Continuous improvement
documentation, improvement
and Future continuous pace, ROI
progress tracking initiatives
Roadmap improvement

39
 APPENDIX 3
INTERNSHIP CERTIFICATE FROM CASE STUDY INDUSTRY

40
 APPENDIX 4
CERTIFICATE FROM THE INTERNATIONAL CONFERENCE ON
NEWER ENGINEERING CONCEPTS AND TECHNOLOGY
(ICONNECT – 2024)

41
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