Maruti Production System

Maruti Production System or MPS draws learning's from our parent company
Suzuki Motor Corporation's concepts on 'lean manufacturing' under Suzuki
Production System -SPS.

Any production facility is essentially a mix of 4 M, which are Man, Machine,

  Materials and Methods. The 3M's namely Muri, Muda and Mura (Japanese term for
Inconvenience, Wastage and Inconsistency) adversely affect productivity.

MPS is a systematic approach to eliminate Muri's (inconveniences if any for shop

floor employees) Mudas (all forms of wastages) and Muras (inconsistencies in
quality) from
  the system so that cost, quality, productivity and safety are under control.
   
Do it right the first time

Under the Maruti Production System (MPS), Maruti engineers capture all aspects of operation on video and scrutinized
each process to identify wastage. Together with workers on the shop floor, layouts were altered, innovative equipment
  and processes were introduced and operations relentlessly made lean and efficient.

According to MPS, there are eight types of wastages in any process namely,
   
Idle Time,
Inventory,
Over Production,
Production Defects,
 
Un-necessary man movement,
Un-necessary material movement,
Un-necessary inspection and
Un-necessary processing.
   
However, if every employee tries to do the job right the first time, wastages due to un-necessary inspection and
processing are eliminated from the system and it is a cost effective approach.
 
A product of poor quality requires repeated inspections, entails wastage in terms of repairs and replacements and
causes loss of time and morale. If we could 'do it right first time', wastage would automatically come down.