Application of Lean approach for reducing weld defects in a valve component: a case study

Purpose The purpose of the study reported in the paper is to apply a structured problem-solving approach based on the Lean approach to analyse weld defects and derive appropriate solutions. Design/methodology/approach Manufacturing organisations involved in welding fabrication are expected to reduce weld defects to attain competitive advantage. Weld defects need to be systematically analysed for valve performance enhancement. In this research study, Lean approach is used to reduce variations and waste by annihilating the root causes for failures that occur during submerged arc welding (SAW) process. Findings The deployment of solutions facilitated weld defect reduction and substantial financial savings for the organisation. Research limitations/implications The framework has been test-implemented for analysing variations and wastes generated in the SAW process. In future, studies could be conducted for assessing different welding processes. Practical implications The proposed Lean framework has been successfully implemented in a large-scale manufacturing unit involved in fabrication work. Originality/value Lean framework has been test-implemented in a large-scale manufacturing organisation involved in weld fabrication work.