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Today, numerous companies have a major opportunity to reduce their costs and customer lead time and cycle time through the application of Lean Manufacturing processes. In recent years, almost every manufacturing industry has been trying to get ‘lean’. Lean thinking represents a set of principles and techniques for the identification and elimination of wastages in manufacturing and administrative processes. Value Stream Mapping (VSM) which is one of the lean manufacturing approaches has emerged as the preferred way to support and implement the lean approach. VSM is a helpful tool to identify the waste and improvement areas. VSM enables a company to see the entire process in both its current and desired future state, and develop the road map that prioritises the projects or tasks to bridge the gap between the current state and the future (lean) state.

Air pollution with the exhaust emission is still a serious problem and an international concern has been raised for its control and restriction. The main problem faced by most of the vehicles today is the emission of NOx which is drastically reduced in the mixture of diesel and LPG popularly known as a dual fuel. In this investigation, the application of CFD in the LPG and air mixture formation in a dual fuel engine (diesel and LPG) has been carried out and the results have been validated by experimental method. Normally LPG is inducted through a gas jet to the inlet manifold of the engine which is placed close to the engine, maintaining an angle of inclination to the air-flow direction. The LPG jet angle is changed in accordance with the injector nozzle angle. The variation of the jet parameters changes the performance of the engine. CFD software has been used to solve this problem and is validated with experimental results.