Open Access Open Access  Restricted Access Subscription or Fee Access

Supply Chain Planning and Management in Assembly Line Automobile Industry

Karam Singh, Jagmail Singh


Yamaha Motors Faridabad has changed the world with their production system. By removing activities in the manufacturing process which were not adding any value to the product, the company could become agile and offer products to the customer with short lead time as well as to a low cost. Companies in other countries needed to change their manufacturing processes in order to stay competitive, and a western variant of the production system used by Yamaha Motors was developed. It was named lean manufacturing. Supply chain management is based on the same concepts as the Yamaha Motors Faridabad and focuses a lot on eliminating non-value adding activities, so-called waste. Waste could come in many different shapes but could, for example, be transportation, overproduction, assembly line management and inventory. Previously, the company has not been exposed to a lot of waste in their manufacturing processes. Besides performing a comprehensive analysis of the current state, the study also includes developing suggestions of a future state with new layout, material carriers and concepts on how to signal for material between different areas. The scope of the study is the operations inside the plant and is kept on a high-level perspective. The research approach to this study has been a deductive approach with a focus on collecting quantitative data and the strategy has been to conduct a single case study with a holistic design. Furthermore, much of the collected data have been primary data and this is one of the reasons why the quality of this study is considered to be high. With the help of supply chain tools such as new assembly design, several improvement areas could be identified. The new state has been several benefits to the company.

Full Text:



Ab Talib MS, Hamid ABA, Too AC. Critical success factors of supply chain management: a literature survey and Pareto analysis. EuroMed J Bus. 2015; 10(2): 234–263p.

Aghazadeh S-M, Hafeznezami S, Najjar L, Huq Z. The influence of work-cells and facility layout on the manufacturing efficiency. J Facil Manag. 2011; 9(3): 213–224p.

Alfa Laval. (2015). Alfa Laval: About Us. [Online] Available from: [Accessed 11 September 2015].

Anon. (2015). University of Michigan, Michigan Engineering. [Online] Available from: [Accessed 25 October 2015].

Anon. (n.d.). Lean Enterprise Institute. [Online] Available from: [Accessed 17 December 2015].

Anon. (n.d.) Six Sigma Material. [Online] Available from: [Accessed 17 December 2015].

Berglund F. (2015). Operations Development Manager, Region US, OD US [Interview] (26 October 2015).

Bhamu J, Sangwan KS. Lean manufacturing: literature review and research issues. Int J Oper Prod Manag. 2014; 34(7): 876–940p.

Bhasin S. An appropriate change strategy for lean success. Manag Dec. 2012; 50(3): 439–458p.

Chapman C. Clean House with Lean 5S. Qual Prog. 2005: 27–32p.

De-Arbulo-Lopez PR, Fortuny-Santos J, Cuatrecasas-Arbos L. Lean manufacturing: costing the value stream. Ind Manag Data Syst. 2013; 647–668(5): 113p.

Emiliani M, Stec D. Using value-stream maps to improve leadership. Leadership Organ. 2004; 25(8): 622–645p.

Erlach K. Value Stream Design—The Way Towards a Lean Factory. 3rd edition. Stuttgart: Springer Verlag; 2013.

Fischer M. Strengthening the empirical base of operations management. Manuf Serv Oper Manag. 2007; 9(4): 368–382p.

Golicic SL, Davis DF, McCarthy TM. A balanced approach to research in supply chain management. In: H. Kotzab, S. Seuring, M. Müller, G. Reiner, editors. Research Methodologies in Supply Chain Management. New York: Physica-Verlag; 2005, pp. 15–30.

Halldórsson Á, Arlbjørn JS. Research methodologies in supply chain management—what do we know? In: H. Kotzab, S. Seuring, M. Müller, G. Reiner, editors. Research Methodologies in Supply Chain Management. Heidelberg: Physica-Verlag; 2005, pp. 107–124.

Harris M.. Lean Enterprise Institute. [Online] Available from: [Accessed 2 December 2015].

Hines P, Rich N. The seven value stream mapping tools. Int J Oper Prod Manag. 1997; 17(1): 46–64p.

Karuppusami G, Gandhinathan R. Pareto analysis of critical success factors of total quality management: a literature review and analysis. TQM Mag. 2006; 18(4): 372–385p.

Lee-Mortimer A. A lean route to manufacturing survival. Assembly Autom. 2006; 26(4): 265–272p.

Liker JK. The Toyota Way: 14 Management Principles from the World's Greatest Manufacturer. New York: McGraw-Hill; 2004.

Matawale CR, Datta S. Leanness metric evaluation platform in fuzzy context. J Model Manag. 2015; 10(2): 238–267p.

Menachof DA, Gibson BJ, Hanna JB, Whiteing AE. An analysis of the value of supply chain management periodicals. Int J Phys Distrib Log Manag. 2009; 39(2): 145–166p.

Meredith J. Building operations management theory through case and field research. J Oper Manag. 1998; 16: 441–454p.

Murugaiah U, Benjamin SJ, Marathamuthu MS, Muthaiyah S. Scrap loss reduction using the 5-whys analysis. Int J Qual Reliab Manag. 2010; 27(5): 527–540p.

Olhager J. Produktionsekonomi. Lund: Studentlitteratur.

Olhager J. Introduktionskurs till examensarbeteninomteknisklogistik. Lund: s.n.

Rother M, Shook J. Learning to See—Value Stream Mapping to Create Value and Eliminate Muda. Brookline: The Lean Enterprise Institute; 1999.

Sanders R. The Pareto principle: its use and abuse. J Prod Brand Manag. 1992; 1(2): 37–40p.

Singh B, Garg S, Sharma S, Grewal C. Lean implementation and its benefits to production industry. Int J Lean Six Sigma. 2010; 1(2): 157–168p.

Singh B, Sharma SK. Value stream mapping as a versatile tool for lean implementation: an Indian case study of a manufacturing firm. Meas Bus Excell. 2009; 13(3): 58–68p.

Singh H, Singh A. Application of lean manufacturing using value stream mapping in an auto-parts manufacturing unit. J Adv Manag Res. 2013; 10(1): 72–84p.

Spens KM, Kovacs G. A content analysis of research approaches in logistics research. Int J Phys Distrib Log Manag. 2006; 36(5): 374–390p.

Stone KB. Four decades of lean: a systematic literature review. Int J Lean Six Sigma. 2012; 3(2): 112–132p.

Stuart I, McCutcheon D, Handfield R, McLachlin R, Samson D. Effective case research in operations management: a process perspective. J Oper Manag. 2002; 20: 419–433p.

Toyota Motor Corporation. (n.d.). Just-in-Time — Philosophy of complete elimination of waste. [Online]. Available from: [Accessed 2 December 2015].

Vinodh S, Somanaathan M, Arvind K. Development of value stream map for achieving leaness in a manufacturing organization. J Eng Des Technol. 2013; 11(2): 129–141p.

Voss C, Tsikriktsis N, Frohlich M. Case research in operations management. Int J Oper Prod Manag. 2002; 22(2): 195–219p.

Vrat P. Materials Management—An integrated Systems Approach. 1st edition. New Delhi: Springer Verlag; 2014.

Yin RK. Case Study Research: Design and Methods. 4th edition. Los Angeles, CA: SAGE Publications, Inc.; 2009.


  • There are currently no refbacks.