Search Results

In the pursuit of manufacturing excellence BorgWarner, Inc., USA has utilized some key aspects of Toyota Production System and General Motors Quality System Basics tools to create a systematic framework called as Borg Warner Production System (BWPS). The goal of BWPS is to have robust manufacturing systems to deliver flawless quality products at lowest possible cost and give hassle free customer experience. This case study covers the BorgWarner Production System implementation experience of DivgiWarner Pvt. Ltd. India, one of the BorgWarner's plant based in Pune and Sirsi, India. The BWPS consists of 7 foundational elements and 23 tactical strategies.

In traditional manufacturing processes a lot of material is wasted in hidden ways. These can be identified through Lean Manufacturing systems. It is proven that the Lean Approach eliminates waste and improves value. This reduces excessive investment in working capital and improves Return on Invested Capital (RoIC). As a result, the shareholder's value is maximized through simultaneously reducing costs and increasing capital efficiency. To demonstrate this we analyzed the production process of the Upper Output Shaft , a key component in a typical drive train assembly like a Four Wheel Drive transfer case, used in a pickup truck or SUV. Value Stream Mapping (VSM) is used to identify and reduce non value-added activities.