Time study is defined as a work measurement technique for recording the times and rates of working for the elements of a specified job carried out under specified conditions, and for analyzing the data so as to obtain the time necessary for carrying out the job at a defined level of performance. A time study was carried out for all operations of a steering knuckle manufacturing line by direct observation. The observed data was shown in Table 1. The figure 1 portrayed that the number of operations which were less than the takt time. Fig2. Showing the current state mapping shows the total cycle time for each operation, change over time and uptime. The process begins by documenting the flow of material and information of the existing process, called the current state. The current state is typically drawn by hand, illustrating the received material, work-in-process, and finished goods inventory, cycle time, lead time, processes, flow of work-in-process between production processes, mode of shipment of finished product to the customers including transportation frequencies and time, and major customers or distribution system. Lean tools involved in lean implementation were assessed using the detailed questionnaire in a five point scale. The overall score of each lean tool represent the leanness level. The leanness level was assessed for 60 points carrying 5 points for each tool. Table 2. showing the Lean tools and Description Table 3. Showing the assessment of lean tools
