Lean Manufacturing Model of Production Management Make to Order Based on QRM to Reduce Order Delivery Times in Metal-Mechanical SMEs

2021 ◽  
pp. 402-409
Author(s):  
Diego Huayllasco-Martinez ◽  
Eduardo Chavez-Ccencho ◽  
Juan Carlos-Peñafiel ◽  
Carlos Raymundo
Keyword(s):  
Lean Manufacturing ◽  
Production Management ◽  
Delivery Times ◽  
Make To Order

Design of Lean Manufacturing Support Systems in Make-to-Order Production

2009 ◽  
Vol 410-411 ◽  
pp. 151-158 ◽  
Author(s):  
Dominik T. Matt
Keyword(s):  
Lean Manufacturing ◽  
Multinational Enterprises ◽  
Material Handling ◽  
Production Systems ◽  
Support Systems ◽  
Far East ◽  
Design Parameters ◽  
Special Focus ◽  
Make To Order ◽  
The Rich

Build-to-order was once the only way in which products were made, but limited the market to only the rich buyers. Mass production contributed to a wider access to products, however with losses in individuality. Finally, mass customization aimed at holding out the promise of both, and “lean” concepts helped to (partly) make it a reality. However, the world has changed significantly since the first introduction of “lean” – especially in the most recent years. European companies are facing a growing international competition in volume markets due to the increasing economical and technical emancipation of low labour cost countries. While multinational enterprises are shifting their manufacturing activities to Far East to keep competitive in terms of costs, small and medium sized companies often have to leave their traditional market segments and retreat into niches. However, smaller production lot sizes and the increasing complexity of product programmes require innovative manufacturing strategies. According to several studies and empirical proves, less than 0,5% of a company’s production lead time is value adding, the bigger part of it is dedicated to waiting, handling and internal transport. This paper presents a new approach for the design of lean manufacturing support systems in make-to-order production systems that have to deal with a huge variety of product types and with high variations in demand. A special focus is given to the design of manual material handling and transport (MMHT) solutions. With the help of axiomatic design principles, a tree of design parameters is derived and translated into generally applicable design rules. With the help of a practical example from make-to-order industry, the validity of the methodology is illustrated.

A Framework for Implementing Lean Manufacturing System in Small and Medium Enterprises

2011 ◽  
Vol 110-116 ◽  
pp. 3997-4003 ◽  
Author(s):  
Jirapat Wanitwattanakosol ◽  
Apichat Sopadang
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing System ◽  
Job Shop ◽  
Small And Medium Enterprises ◽  
Phase 1 ◽  
Optimization Technique ◽  
Value Stream Mapping ◽  
Two Phase ◽  
Make To Order ◽  
Medium Enterprises

—In this paper, a conceptual framework to apply many techniques for implementing lean in the high-variety low-volume (HVLV) environment is presented. Lean production has increasingly being implemented as a potential solution for many organizations. Anyway, the lean formula is applicable directly only to the make-to-stock business, but the make-to-order (MTO) product environment has to adapt lean manufacturing principle. The method of this paper has a two-phase quantitative framework to transform small and medium enterprises (SMEs) to be lean. Phase 1 has three interrelated components: (1) re-engineering an organization by using the power of computer simulation combined with business process. (2) Value stream mapping (VSM) is used to create a map of both value and waste in a given process. This tool has also a main drawback for job shop facility because many value streams are composed of hundreds of industrial parts and products. (3) Integrative supplier relationship is one of the most critical factors to maintain an advantage in the increasing levels of competition. Phase 2 performs a just in time production schedule by using ant colony optimization technique combines with a simulation tool. The aims of this paper are to develop a suitable lean manufacturing system for SMEs and to study the performance of the system for improving effectiveness. The result shows how to combine lean concept with simulation optimization, the step of this framework to obtain the optimization solution.

scholarly journals Strategic Groups and Competitive Priorities in Lean Production Environments: Challenges of Production Management

2018 ◽  
Vol 18 (2) ◽  
Author(s):  
Orlando Roque Da Silva ◽  
Delvio Venanzi ◽  
Haroldo Lhou Haegawa ◽  
Diogo Faustino
Keyword(s):  
Lean Manufacturing ◽  
Production Management ◽  
Lean Production ◽  
Manufacturing Companies ◽  
Strategic Groups ◽  
Strategic Orientations ◽  
Production Environments ◽  
Auto Parts ◽  
Production Practices ◽  
The Relationship

This paper explores how the choices and implementation of lean production practices are influenced by performance goals prioritized by firms in the context of operations strategy. We analyzed a set of fifty-six companies in the auto parts industry in Campinas and Jundiai region, divided into four strategic groups. These groups of firms that adopt similar strategic orientations were used to investigate the relationship between implementation of lean manufacturing practices and choice of performance objectives. The results suggest that consideration of strategic groups can improve the understanding of how performance objectives can define lean manufacturing practices adopted by manufacturing companies.

scholarly journals Analytical hierarchy process - bocr applied for the best lean project selection for production lines

2020 ◽  
Vol 11 (1) ◽  
pp. 054
Author(s):  
José Antonio De Miranda Lammoglia ◽  
Nilson Brandalise ◽  
Cecilia Toledo Hernandez
Keyword(s):  
Decision Making ◽  
Lean Manufacturing ◽  
Production Management ◽  
Production Systems ◽  
Management Strategies ◽  
Investment Project ◽  
Production Volume ◽  
Production Lines ◽  
Global Competitiveness ◽  
Investment Projects

The scenario of global competitiveness demands more and more of the organizations the search for continuous improvement. For survival, in the face of adverse market conditions, modern production management strategies are essential to make production processes increasingly efficient, lean and sustainable, minimizing losses in their production systems. In this sense, when thinking about changes in production lines, in search of improvements in their process, criteria that provide Benefits, Opportunities, Costs and Risks (BOCR) should be considered. In this way, managers and executives should rely on tools and methods that allow them to guide their decisions in a clear way. The objective of this work is to apply a method of Decision Making with Multiple Criteria to the alternatives of investment projects in production lines in Lean Manufacturing concept. As a general result, it was possible to observe the applicability of the AHP BOCR method for the decision-making case involving several criteria and subcriteria for choosing the Lean investment project in the steel environment, the preferred alternative being the discontinuity of the production line 1 and the absorption of their respective production volume by production lines 2 and 3 through investments in them.

scholarly journals Smart Production Planning and Control: Concept, Use-Cases and Sustainability Implications

2020 ◽  
Vol 12 (9) ◽  
pp. 3791 ◽  
Author(s):  
Olumide Emmanuel Oluyisola ◽  
Fabio Sgarbossa ◽  
Jan Ola Strandhagen
Keyword(s):  
Production Planning ◽  
Production Management ◽  
Production Systems ◽  
Production Planning And Control ◽  
Market Uncertainty ◽  
Planning And Control ◽  
Make To Order ◽  
Smart Technologies ◽  
And Control ◽  
Process Strategy

Many companies are struggling to manage their production systems due to increasing market uncertainty. While emerging ‘smart’ technologies such as the internet of things, machine learning, and cloud computing have been touted as having the potential to transform production management, the realities of their adoption and use have been much more challenging than anticipated. In this paper, we explore these challenges and present a conceptual model, a use-case matrix and a product–process framework for a smart production planning and control (smart PPC) system and illustrate the use of these artefacts through four case companies. The presented model adopts an incremental approach that companies with limited resources could employ in improving their PPC process in the context of industry 4.0 and sustainability. The results reveal that while make-to-order companies are more likely to derive greater benefits from a smart product strategy, make-to-stock companies are more likely to derive the most benefit from pursuing a smart process strategy, and consequently a smart PPC solution.

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 Lean Manufacturing Model for production management to increase SME productivity in the non-primary manufacturing sector

2020 ◽  
Vol 796 ◽  
pp. 012019
Author(s):  
S Flores-Meza ◽  
J Limaymanta-Perales ◽  
J Eyzaquirre-Munarriz ◽  
C Raymundo-Ibañez ◽  
M Perez
Keyword(s):  
Lean Manufacturing ◽  
Production Management ◽  
Manufacturing Sector

scholarly journals A Model of Lean Management for Organizational Innovation: Cases in Visegrád and AFTA

2019 ◽  
Vol 1 (1) ◽  
pp. 532-541
Author(s):  
Tuan-anh Tran ◽  
Rajab Ghabour ◽  
My Nguyen ◽  
Miklós Daróczi
Keyword(s):  
Lean Manufacturing ◽  
Production Management ◽  
Organizational Innovation ◽  
Free Trade Area ◽  
Labor Cost ◽  
Lean Management ◽  
Managerial Decision ◽  
Management Philosophy ◽  
Trade Blocs ◽  
Trade Area

AbstractOriginated as a production management philosophy, Lean Manufacturing has successfully transferred and implemented globally. Lean genealogy studies have been conducted, indicating the essential concept now evolves to Lean Management (LM), which is applicable to many branches of production and services management, viz quality and productivity, human resources, knowledge and technology, etc. Innovation has been made to ensure a smooth customization of knowledge and principles, tailored to each organization who is eager to implement this state-of-the-art management system. However, failures are becoming commonplace due to the lack of understanding the core values, and insufficient intensification of compensation for cultural differences. In this paper, cases of implementing LM across the Visegrád group (V4) and the ASEAN Free Trade Area (AFTA) from previous literature are taken into consideration. Factors that differentiate the characteristic of LM are brought to discussion. Therefore, the discovered gap between the two trade blocs urges the in-depth amendment and modification of employed concepts, tools, etc. A model is consequently elaborated, which aims at facilitate the managerial decision-making process regarding knowledge transfer of LM between V4 and AFTA, based on critical factors related to human, technology and culture, i.e. Labor cost, Manual requirement, Awareness, Continuous Improvement culture. This model can be used to predict the change should be made, or the criterion should be fulfilled to transfer the implementation and knowledge of LM effectively.

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