Abstract
The Automotive Supply Chain (ASC) industries in South Africa (SA) are thriving to eliminate the bottlenecks by implementing Lean Manufacturing (LM) techniques in the production line. The paper seeks to identify the bottlenecks by Gemba walks and develop methods to eliminate the eight wastes using the theory of constrains (TOC) and the Strength, Weakness, Opportunities and Threats (SWOT) analysis techniques. The bottleneck is exploited using the (TOC), error proofing Poka Yoka and intelligent Jidoka tools on the production machines. The use of green materials, trained personnel, good housekeeping, and inventory control together with a safe and health work environment increased throughput rates to meet customer needs and job satisfaction. The Total Productive Maintenance (TPM) was used to correct the looming machine failure and improve the Overall Equipment Effectiveness (OEE).