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

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.