• kaizen
• lean manufacturing
• continuous improvement
• automotive

This thesis looks at the application of continuous improvement techniques in a complex manufacturing system. The activities described took place between September 2014 and March 2015 in a world leader automotive OEM supplier (steering wheels production). This Master's thesis is supposed to illustrate a strategy for continuous improvement and come up with recommendation for the implementation in the manufacturing area. Despite the relatively short period of time, a comprehensive approach for these has been developed.

The target operations are characterized by part complexity with more than 300 part numbers, scheduling complexity with internal demand unpredictability and the need to accomodate new product and process development, and process complexity with strict requirements that stretch the capabilities of the processes. In addition, the company is affected by an important personnel turnover which increases the efforts necessary to succeed with such lean manufacturing techniques.

The pursued objectives of increasing productivity and quality are both mutually interrelated to each other. This fact has required continuous improvement in current working methods and environment of the company, involving and collaborating with different departments. The approach followed during this thesis work is "kaizen" which means improving the existing methods in a way to outline problems and to solve them through a little but constant effort.

The areas where the improvement efforts have been notable are Die casting and Foaming, therefore the thesis work will be focused on them. The implementation strategy has been suited on the area to be addressed so the lean techniques used may vary as the order different tasks have been done.

In the first part a theoretical framework on continuous improvement is presented. This has been developed starting from work standardization which represents the fundamental basis for process improvement. Work standardization is therefore strictly necessary for a thorough lean tools utilisation and confirmation of their effectiveness.

The second part is dedicated to the presentation of real cases of continuous improvement projects where the author of this thesis provided a remarkable contribute. These projects refer in particular to focused improvement and autonomous maintenance activities. Where possible also the impact on the business in terms of cost savings is presented.

The appendixes recall some auxiliary documentation together with other secondary activities.