Sustainability of the Production Process by Applying Lean Manufacturing Through the PDCA Cycle – A Case Study in the Machinery Industry

2021 ◽  
pp. 199-211
Author(s):  
Marko Milosevic ◽  
Marko Djapan ◽  
Roberto D’Amato ◽  
Nicolae Ungureanu ◽  
Alessandro Ruggiero
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Machinery Industry ◽  
Pdca Cycle

scholarly journals PDCA Cycle – Tool for Improvement of the Business Processes – Case Study

TEM Journal ◽  
2021 ◽  
pp. 1336-1347
Author(s):  
Peter Malega ◽  
Naqib Daneshjo ◽  
Vladimír Rudy ◽  
Peter Drábik
Keyword(s):  
Quality Management ◽  
Production Process ◽  
Process Optimization ◽  
Critical Points ◽  
Business Processes ◽  
Management Tools ◽  
Pdca Cycle ◽  
Corrective Actions

The goal of this paper is to find suitable solutions for process optimization using PDCA methodology and quality management tools. It was realized in the company that is oriented on the assembly of key sets, locks and handles. It analyzes chosen assembly processes, their critical points and identifies root causes of problems that might occur during assembly. For this purpose, different quality methods and tools are used. In this paper there are also defined the corrective actions to avoid recurrence of identified problems, implementation of these actions in production process and its standardization.

scholarly journals Applying the PDCA Cycle to Reduce the Defects in the Manufacturing Industry. A Case Study

2018 ◽  
Author(s):  
Arturo Realyvásquez-Vargas ◽  
Karina Cecilia Arredondo-Soto ◽  
Teresa Carrillo ◽  
Gustavo Ravelo
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Manufacturing Companies ◽  
Delivery Times ◽  
Pdca Cycle ◽  
Increasing Demand ◽  
Quality Of Products

Defects are considered one of the wastes in manufacturing systems that negatively affect the delivery times, cost and quality of products leading to manufacturing companies facing a critical situation with the customers and to not comply with the IPC-A-610E standard for the acceptability of electronic components. This is the case is a manufacturing company located in Tijuana, Mexico. Due to an increasing demand on the products manufactured by this company, several defects have been detected in the welding process of electronic boards, as well as in the components named Thru-Holes. It is for this reason that this paper presents a lean manufacturing application case study. The objective of this research is to reduce at least 20% the defects generated during the welding process. In addition, it is intended to increase 20% the capacity of 3 double production lines where electronic boards are processed. As method, the PDCA cycle, is applied. The Pareto charts and the flowchart are used as support tools. As results, defects decreased 65%, 79% and 77% in three analyzed product models. As conclusion, the PDCA cycle, the Pareto charts, and the flowchart are excellent quality tools that help decrease the number of defective components.

scholarly journals Applying Lean Manufacturing in the Production Process of Rolling Doors: A Case Study

2020 ◽  
Vol 13 (7) ◽  
pp. 1774-1781
Author(s):  
Leandro L. Lorente Leyva ◽  
Mishell A. Yerovi Huaca ◽  
Yakcleem Montero Santos ◽  
Ramiro V. Saraguro Piarpuezan ◽  
Israel D. Herrera Granda ◽  
...  
Keyword(s):  
Production Process ◽  
Lean Manufacturing

scholarly journals Using lean manufacturing tools to reduce waste and loss in the production process - A case study on a production plant for bottling water -: استخدام أدوات التصنيع الرشيق لتقليل الهدر والضياع في العملية الإنتاجية – دراسة حالة في معمل إنتاجي لتعبئة المياه –

2021 ◽  
Vol 5 (3) ◽  
Author(s):  
Hanan Saleh Jabr
Keyword(s):  
Production Process ◽  
Analytical Method ◽  
Lean Manufacturing ◽  
Raw Materials ◽  
Production Plant ◽  
Market Needs ◽  
Reducing Costs ◽  
Materials Used ◽  
Basic Hypothesis

The research aims to identify the problems that hinder the production process and the most important of these problems is the waste and waste of the available resources, whether in the raw materials used in production or the waste of the time it takes to complete the production process. And the obstacles and benefits achieved from them, using the descriptive analytical method to study the basic hypothesis that says that the use of lean manufacturing tools leads to reducing waste and loss in the production process. The research has concluded that the application of the lean system leads to reducing waste and loss in the production process and thus create value for the customer The use of lean manufacturing tools creates products that meet market needs and according to the level of demand. Among the most important recommendations is the necessity for productive institutions to take into account product quality and not focus on reducing costs in order to meet the customer's desire.

scholarly journals Implementación de la manufactura esbelta en una línea de arneses eléctricos automotrices

2019 ◽  
pp. 21-29
Author(s):  
Adolfo Cano-Carrasco ◽  
María del Carmen Vásquez-Torres ◽  
Elizabeth González-Valenzuela ◽  
Héctor Bellizia- Guzmán
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Assembly Line ◽  
Pull System ◽  
Final Assembly ◽  
Successful Case ◽  
Manufacturing Company

This research analyzes the implementation of the Lean Manufacturing philosophy through a case study in the final assembly line in an electric automotive harness manufacturing company and intends to demonstrate that the current waste from the production process under study will be eliminated through the sustainable application of The Theory of Lean Manufacturing. The methodology used was carried out with the help of the Deming circle: Plan objectives, model line, equipment, training, Execute: design stations, Recognize waste, Establish flow, create mixed lots, calculate Tak-time, Determine matching operations, Determine pull system, Verify: launch and Act: determine verification and monitoring. Subsequently, the programs applied and the activities used for the development of the lean manufacturing philosophy were analyzed. The main contribution is to share the results of a successful case in the implementation of the lean manufacturing philosophy when analyzing the effectiveness of the programs and support activities in its development.

scholarly journals Applying the Plan-Do-Check-Act (PDCA) Cycle to Reduce the Defects in the Manufacturing Industry. A Case Study

2018 ◽  
Vol 8 (11) ◽  
pp. 2181 ◽  
Author(s):  
Arturo Realyvásquez-Vargas ◽  
Karina Arredondo-Soto ◽  
Teresa Carrillo-Gutiérrez ◽  
Gustavo Ravelo
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing Industry ◽  
Welding Process ◽  
Manufacturing Companies ◽  
Delivery Times ◽  
Pdca Cycle ◽  
Increasing Demand ◽  
Quality Of Products

Defects are considered as one of the wastes in manufacturing systems that negatively affect the delivery times, cost and quality of products leading to manufacturing companies facing a critical situation with the customers and to not comply with the IPC-A-610E standard for the acceptability of electronic components. This is the case is a manufacturing company located in Tijuana, Mexico. Due to an increasing demand on the products manufactured by this company, several defects have been detected in the welding process of electronic boards, as well as in the components named Thru-Holes. It is for this reason that this paper presents a lean manufacturing application case study. The objective of this research is to reduce at least 20% the defects that are generated during the welding process. In addition, it is intended to increase 20% the capacity of three double production lines where electronic boards are processed. As method, the Plan-Do-Check-Act (PDCA) cycle, is applied. The Pareto charts and the flowchart are used as support tools. As results, defects decreased 65%, 79%, and 77% in three analyzed product models. As conclusion, the PDCA cycle, the Pareto charts, and the flowchart are excellent quality tools that help to decrease the number of defective components.

scholarly journals MWO Line Optimization Applying Lean Manufacturing Methodology: PIM Case Study

2019 ◽  
Vol 7 (11) ◽  
pp. 776-787
Author(s):  
Aline Azevedo Eleutério ◽  
Alexandra Priscilla Tregue Costa ◽  
David Barbosa de Alencar ◽  
Antônio Estanislau Sanches
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Added Value ◽  
Minimal Amount ◽  
Profit Margins ◽  
Work In Process ◽  
Quality Tools ◽  
Lean Methods ◽  
Very High

With the increasing competitiveness in the market and the constant development of technologies, today companies are constantly improving, the managers' concern is to achieve maximum process productivity with minimum losses and waste, thus reducing the value to the maximum. aggregate to the product and taking considerable profit margins from sales, so it is of paramount importance to have a lean production process, with well-balanced production times, a minimal amount of work in process and especially a minimal amount of labor , which has very high costs that generates added value directly in the product. In this study was applied the methodology, observation, quantitative and deductive based on theoretical references in order to maximize the efficiency of the production process, through the use of some Lean methods and quality tools as a way of discourse for process improvement also applying process balancing with the primary purpose of reducing the amount of direct labor. Thus the present study presented satisfactory results increasing the efficiency of the microwave oven production line, with the reduction of a direct operator, bringing a leaner and more efficient process.

scholarly journals Using Enterprise Architecture to Integrate Lean Manufacturing, Digitalization, and Sustainability: A Lean Enterprise Case Study in the Chemical Industry

2021 ◽  
Vol 13 (9) ◽  
pp. 4851
Author(s):  
Ming-Hui Liao ◽  
Chi-Tai Wang
Keyword(s):  
Chemical Industry ◽  
Lean Manufacturing ◽  
Enterprise Architecture ◽  
Raw Materials ◽  
Core Competencies ◽  
Sustainable Business ◽  
Business Transformation ◽  
Lean Enterprise ◽  
Architecture Framework

The chemical industry has sustained the development of global economies by providing an astonishing variety of products and services, while also consuming massive amounts of raw materials and energy. Chemical firms are currently under tremendous pressure to become lean enterprises capable of executing not only traditional lean manufacturing practices but also emerging competing strategies of digitalization and sustainability. All of these are core competencies required for chemical firms to compete and thrive in future markets. Unfortunately, reports of successful transformation are so rare among chemical firms that acquiring the details of these cases would seem an almost impossible mission. The severe lack of knowledge about these business transformations thus provided a strong motivation for this research. Using The Open Group Architecture Framework, we performed an in-depth study on a real business transformation occurring at a major international chemical corporation, extracting the architecture framework possibly adopted by this firm to become a lean enterprise. This comprehensive case study resulted in two major contributions to the field of sustainable business transformation: (1) a custom lean enterprise architecture framework applicable to common chemical firms making a similar transformation, and (2) a lean enterprise model developed to assist chemical firms in comprehending the intricate and complicated dynamics between lean manufacturing, digitalization, and sustainability.

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