Lean tools deployment study in the manufacturing sector in the state of Tamil Nadu

Abstract

This research aims to deploy lean tools in the manufacturing sector of Tamil Nadu. The study employs a quantitative and analytical research methodology to assess how lean tools affect the quality and productivity of the automotive manufacturing industry. Of the 26 Lean tools considered, four – 5S, Kaizen, Total Productive Maintenance and value stream mapping (VSM) – were selected for implementation to address defects, downtime and workflow inefficiencies. Data were collected through structured surveys, field observations, shop-floor defect analyses and time-study records. Businesses in the automobile manufacturing sector can benefit from this research by learning valuable lessons. The validity of lean tools was proven by review of the experimental findings, which showed a 24.1% increase in productivity, a 48.2% reduction in defects and a 10.7% improvement in machine uptime. Manufacturing companies should focus on creating a lean culture by obtaining ongoing top management commitment and funding thorough, in-depth training in lean practices at all organizational levels in order to optimize returns on lean investments. While lean literature is extensive, its application often assumes a high-resource environment with standardized labor practices. This study advances the field by exploring how dynamic capabilities (DC) are developed within the Tier-2 and Tier-3 manufacturing clusters of Tamil Nadu. It provides new insights into how lean tools function as “stabilizing mechanisms” in environments characterized by high labor volatility and semi-formal supply chain structures, offering a model for lean deployment that moves beyond mere tool application to the institutionalization of organizational routines in emerging economies.