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<p>Indian automotive SMEs face persistent inefficiencies in die changeovers, tool setups, and traceability, undermining their competitiveness and ISO 9001:2015 compliance. While Lean tools like SMED and ERP systems individually offer performance improvements, their combined application remains underutilized in SMEs. This study presents a structured four-phase ERP-Lean integration model validated in a Chennai based tooling SME. The approach began with diagnostic analysis and time-motion studies to identify inefficiencies, followed by Lean-SMED deployment with standardized setups, ERP customization, and KPI based performance evaluation. Key ERP modules Production Planning, Quality, Inventory, and Maintenance were configured to support real-time visibility and ISO-aligned digital workflows. Results showed a 95.2% reduction in die changeover time, 88.9% reduction in downtime, 72.4% reduction in rejection rate (PPM), and a 148.6% improvement in setup time utilization. Inventory turnover improved by 54.7%, and traceability resolution time reduced by 77.1%. This integration fostered process discipline, reduced variability, and improved compliance audit outcomes. The research concludes that ERP-Lean synergy forms a replicable model for SMEs in high-mix, resource sensitive manufacturing sectors aiming to transition toward Industry 4.0 readiness and ISO conformity.</p>

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Integrated ERP lean model for quality enhancement and operational excellence in SME based automotive mould manufacturing

  • 期刊论文

  • 出版模式：

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  • 发表日期：

    2025年10月15日

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  • A. Bhaskar,
  • A. Devaraju

摘要

Indian automotive SMEs face persistent inefficiencies in die changeovers, tool setups, and traceability, undermining their competitiveness and ISO 9001:2015 compliance. While Lean tools like SMED and ERP systems individually offer performance improvements, their combined application remains underutilized in SMEs. This study presents a structured four-phase ERP-Lean integration model validated in a Chennai based tooling SME. The approach began with diagnostic analysis and time-motion studies to identify inefficiencies, followed by Lean-SMED deployment with standardized setups, ERP customization, and KPI based performance evaluation. Key ERP modules Production Planning, Quality, Inventory, and Maintenance were configured to support real-time visibility and ISO-aligned digital workflows. Results showed a 95.2% reduction in die changeover time, 88.9% reduction in downtime, 72.4% reduction in rejection rate (PPM), and a 148.6% improvement in setup time utilization. Inventory turnover improved by 54.7%, and traceability resolution time reduced by 77.1%. This integration fostered process discipline, reduced variability, and improved compliance audit outcomes. The research concludes that ERP-Lean synergy forms a replicable model for SMEs in high-mix, resource sensitive manufacturing sectors aiming to transition toward Industry 4.0 readiness and ISO conformity.