This document is intended for anyone working in any Indian industry. It includes a “Questionnaire survey” which includes...
Lean philosophies and competitiveness of Indian industries Questionnaire for Survey A. Industry Profile A.1 Name:A.2 Turn-Over:A.3 Industry Type: -
Process Industry Electronics Other …………………………….
Textile
Automobile
A.4 Please list the major products of your organization:1……………………………2………………………………….3…………………………. A.5 Number of Employees: than 500 A.6 Years of establishment 15
1-50
0-5
A.7 Name of Respondent (optional):-
A.8 Designation:-
50-200
5-10
200-350
10-15
350 -500
More
More than
B.1:- Please rate the following lean practices related to process and equipment in context to lean implementation in your organization on a five point likert scale i.e. 1- Very poor, 2-Poor, 3-Fair, 4-Good, 5- Very Good.
Sr. No.
Lean Practice
Extent of implementation 1
1 2
6 7 8 9
Preventive maintenance JIT/continuous flow production Cycle time reduction Cellular manufacturing Single piece flow production/one piece flow Zero defects Poka yoke/error proofing Scrap reduction Kaizen
10
Agile manufacturing
11
2 bin auto replenishment system
12
Heijunka/production smoothening/line balancing
13
Single minute die exchange
14
5s
15 16 17
Automation/jidoka Andon Setup time reduction/quick changeover techniques
18
Total productive maintenance
3 4 5
2
3
4
5
B.2:- Please rate the following lean practices related to manufacturing planning and
control in context to lean implementation in your organization on a five point likert scale i.e. 1- Very poor, 2-Poor, 3-Fair, 4-Good, 5- Very Good.
1 2
5 6 7 8 9
Total quality management Pull system/kanban/pull production Lot size reduction/small lot size/batch size reduction Continuous improvement program Value stream mapping (vsm) Inventory management Workplace organization Standardized work Simulation
10
Supply chain management
11
Visual management/visual control/visual factory
12
Production stop policy
13 14
Group technology Takt time
3 4
B.3:- Please rate the following lean practices related to Human Resource in context to lean implementation in your organization on a five point likert scale i.e. 1- Very poor, 2-Poor, 3-Fair, 4-Good, 5- Very Good.
1
Cross functional team/flexible workforce/cross trained employees/multi-skill workers 2 Human resource management C.1 Please rate the following performance parameters related to business /finance performance in context to lean implementation in your organization on a five point likert scale i.e. 1- Very Poor, 2- Poor, 3-Fair, 4-Good, 5-Very Good:-
Sr. No
Performance parameter
Extent of change
1
1
Increase in productivity
2
Decrease in manufacturing cost/unit cost of manufacturing
3 4 5
Increase in market share Increase in turnover Increase in annual sales revenue
6
Increase in growth rate in rupees sales
7
Increase in growth rate in unit sales
8
Increase in profit
9
Increase in sales per employee
10
Decrease in total cost of production
11
Increase in return on investments
12
Increase in return on sales
13
Increase in return on assets
2
3
4
5
C.2 Please rate the following performance parameters related to equipment and process in context to lean implementation in your organization on a five point likert scale i.e. 1- Very Poor, 2- Poor, 3-Fair, 4-Good, 5-Very Good:-
1 2
Decrease in delivery speed /delivery lead time Increase in flexibility in production
3
Increase in capacity utilization /shop utilization/better utilization of resources
4
Decrease in inventory
5
Decrease in manufacturing cycle time
6
Decrease in changeover time/setup time
7
Decrease in defect rate/rejection rate / % rejection
8
Decrease in work in progress
9
Decrease in waste/scrap and rework
10
Decrease in % of time machines are standing due to malfunction
11
Decrease in equipment failure rate
C.3 Please rate the following performance parameters related to human behaviour
in context to lean implementation in your organization on a five point likert scale i.e. 1- Very Poor, 2- Poor, 3-Fair, 4-Good, 5-Very Good:-
1 2
Increase in labor productivity Increase in employee satisfaction
3
Increase in customer satisfaction
4
Increase in customer return rates/customer retention
D Please rate your organization status in 100 points for lean implementation : Assessment out of 100:-
REMARKS(if any):…………………………………………………………………………………………… …………………………………………………………………………………………… …………………………………………………………………………………………… …………………………………………………………………………………………… …………………………………………………………………………………………… …………………………………………………………………………………………… …………………………………………………………………………………………… …………………………………………………………………………………………… …………………………………………………………………………………………… …………………………………………………………………………………………… ………………………… After filling the entire questionnaire, please mail me back on
[email protected] Regards:Sahil Dhankhar M.Tech. Student, Department of Mechanical Engineering,
U.I.E.T., MDU, Rohtak, Haryana (124001).
