A Systematic Approach to Evaluate the Process Improvement in Lean Manufacturing Organizations

2012 ◽  
pp. 65-70 ◽  
Author(s):  
M. A. Amin ◽  
M. A. Karim
Keyword(s):  
Process Improvement ◽  
Lean Manufacturing ◽  
Systematic Approach ◽  
Manufacturing Organizations

Process Improvement of Brake Lever Production Using DMAIC (+)

2011 ◽  
Author(s):  
Chittaranjan Sahay ◽  
Suhash Ghosh ◽  
Pradeep Kumar Bheemarthi
Keyword(s):  
Data Analysis ◽  
Problem Solving ◽  
Process Improvement ◽  
Six Sigma ◽  
Lean Manufacturing ◽  
Cost Effective ◽  
Poor Quality ◽  
Statistical Process ◽  
Automotive Components ◽  
The Cost

This work describes a strategy to reduce the cost associated with poor quality, by reducing the parts per million defects by Defining, Measuring, Analyzing, Implementing and Controlling (DMAIC) the production process. The method uses a combination of principles of Six Sigma applications, Lean Manufacturing and Shanin Strategy. The process has been used in analyzing the manufacturing lines of a brake lever at a Connecticut automotive components manufacturing company for reducing the cost associated with the production of nonconforming parts. The analysis was carried out with the help of the data collected on nonconformance parts and the application of phase change rules from DMAIC (+). Data analysis was carried out on statistical process control softwares, MINITAB and SPC XL 2000. Although, the problem of tight bushing existed on only one line of the brake lever assembly, this problem solving approach has solved the tight bushing problems on all assembly and alternates lines in a time- and cost-effective way.

A systematic literature review of lean manufacturing implementation in manufacturing-based sectors of the developing and developed countries

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Catherine Maware ◽  
Modestus Okechukwu Okwu ◽  
Olufemi Adetunji
Keyword(s):  
Developing Countries ◽  
Literature Review ◽  
Lean Manufacturing ◽  
Negative Impact ◽  
Developed Countries ◽  
Manufacturing Industries ◽  
Preliminary Review ◽  
Content Type ◽  
Manufacturing Organizations ◽  
Developing And Developed Countries

Purpose This study aims to comparatively discuss the effect of lean manufacturing (LM) implementation in the manufacturing sectors of developing and developed countries. Design/methodology/approach An in-depth literature review focused on previous research published between 2015 and March 2020. The papers published by the databases such as Google Scholar, Scopus, ProQuest and Web of Science were used in the study. A total of 63 studies that focused on LM application in manufacturing industries in developing and developed countries were used in the research. Findings It was observed that LM improves operational performance for manufacturing organizations in developing and developed countries. Small and medium-sized enterprises in both developed and developing countries have difficulties transforming their organizations into lean organizations compared to large enterprises. Furthermore, the review also found that there seems to have been no paper had reported the negative impact of implementing LM in manufacturing industries in developing and developed countries from 2015 to March 2020. Research limitations/implications The study used research papers written between January 2015 and March 2020 and only considered manufacturing organizations from developed and developing nations. Practical implications The study provides more insight into LM implementation in developing and developed countries. It gives the LM practices and the implications of applying these practices in manufacturing organizations for developing and developed countries. Originality/value A preliminary review of papers indicated that this seems to be the first paper that comparatively studies how LM implementation has affected manufacturing organizations in developed and developing countries. The study also assessed the LM practices commonly used by the manufacturing industries in developing and developed countries.

A Case Study in Extended Value Engineering

2002 ◽  
Author(s):  
R. Anderson ◽  
R. Sturges
Keyword(s):  
Process Improvement ◽  
Cost Reduction ◽  
Systematic Approach ◽  
Value Engineering ◽  
Cost Comparison ◽  
Mining Equipment ◽  
Analysis Process ◽  
Extended Value ◽  
Product And Process

Extended value engineering techniques provide an efficient, systematic approach to expose unnecessary costs, spur innovation, and direct efforts toward product and process improvement. Extended value engineering involves the comprehensive application of function diagramming, cost/cycle analysis, process diagramming, and competitive cost comparison. The application of these techniques to a mining equipment manufacturer, specifically to an ore haulage vehicle, is described in terms of cost reduction and manufacturing process improvement.

scholarly journals A LEAN MANAGEMENT APPROACH FOR THE ROMANIAN TEXTILE AND CLOTHING INDUSTRY

2019 ◽  
Vol 9 (2) ◽  
pp. 21-31
Author(s):  
Adriana DIMA ◽  
◽  
Ruxandra DINULESCU ◽  
Keyword(s):  
Lean Manufacturing ◽  
Textile Industry ◽  
Systematic Approach ◽  
Continuous Process ◽  
Value Added ◽  
Process Industry ◽  
Clothing Industry ◽  
Management Approach ◽  
Lean Management ◽  
Reducing Costs

Lean management represents a systematic approach used for identifying and eliminating waste and non-value added activities from different industries, including the textile industry. Even if the lean manufacturing concept has shown important results in continuous process industry, the textile industry represents a good area for implementing this methodology targeting as a main objective the action of eliminating waste, thus reducing costs and therefore, increasing productivity. Being a customer oriented process, the system has the ability to eliminate a significant part of waste from the Romanian textile industry. As a result, this is an incipient study aimed to present the benefits of implementing Lean Management in the Romanian textile industry, through its improvement tools, as well as presenting a theoretical economic impact for a textile company. Also, taking into consideration that Lean Management is not yet applied in the Romanian textile field, the study will present a part of the areas which would need the Lean implementation, as well as further actions to be taken in order to improve productivity in textile industry.

Hoshin Kanri and A3: a proposal for integrating variability into the policy deployment process

2019 ◽  
Vol 31 (2) ◽  
pp. 118-135 ◽  
Author(s):  
Guilherme Tortorella ◽  
Paulo A. Cauchick-Miguel ◽  
Paolo Gaiardelli
Keyword(s):  
Lean Manufacturing ◽  
Systematic Approach ◽  
Daily Routine ◽  
Senior Managers ◽  
Content Type ◽  
Organizational Policies ◽  
Market Leader ◽  
Auto Parts ◽  
Parts Manufacturing ◽  
Practical Implications

Purpose The purpose of this paper is to propose a methodology to support the Hoshin Kanri (HK) process taking into account the variance of senior managers’ perspective regarding the relationships among objectives, key performance indicators and continuous improvement (CI) projects. Design/methodology/approach A four-step methodology incorporates the A3 report into the HK, whose deployment was weighted by the variability among managers’ perception about the importance of each decision. This methodology was applied in a market-leader Mexican auto parts manufacturing company that is undergoing a Lean Manufacturing (LM) implementation. Findings The results indicate that the proposed methodology provides an easier approach to consolidate different perspectives and weight the importance of CI projects. Moreover, it minimizes the possibility of managerial conflicts or the influence of a determined senior manager on others’ opinions during the deployment and prioritization. Practical implications This work may be of great interest to managers, consultants and professionals who deal with the implementation of LM and wish to prioritize the importance of CI projects within the perspective of HK. Originality/value HK provides a systematic approach to integrate strategic management with daily routine management through an adequate deployment of organizational policies to all levels. However, companies usually struggle with several issues such as the style of senior managers and consensus establishment among different opinions, which emphasizes the relevance of the proposed methodology in this study.

Process Improvement at Automotive Assembly Line Using Line Balancing and Lean Manufacturing Approach

2020 ◽  
Vol 899 ◽  
pp. 268-274
Author(s):  
Mohamad Hafizdudin bin Tajul Arifin ◽  
Wan Emri Wan Abdul Rahman
Keyword(s):  
Process Improvement ◽  
Automotive Industry ◽  
Manufacturing Process ◽  
Production Line ◽  
Lean Manufacturing ◽  
Assembly Line ◽  
Line Balancing ◽  
Automotive Company ◽  
Automotive Assembly ◽  
Current Production

The aim of this study is to analyze the existing production line in the automotive industry and proposed a layout of improved production line in the manufacturing process and obtain the optimum rate of production time. Thus, line balancing method and Yamazumi Chart was utilized to analyze the current and proposed production line. The collection of the data of the existing production line was conducted at one of the automotive company in Malaysia. From the analysis of current production line, two improved layout were proposed and evaluated. The proposed layout was selected based on a balanced production line and ability to meet customer demand. A balanced production line will ensure smooth process and eliminate wastage during operation

scholarly journals Implementation of Quality Filter Mapping (QFM) in Hot Press Using Lean Manufacturing To Eliminate Waste

2021 ◽  
Vol 1 (2) ◽  
Author(s):  
Muhamad Yasin ◽  
Lukmandono
Keyword(s):  
Production Line ◽  
Lean Manufacturing ◽  
Systematic Approach ◽  
Main Product ◽  
Hot Press ◽  
Customer Demand ◽  
Manufacturing Company ◽  
The Face ◽  
Press Time

PT Sakari Sumber Abadi is a manufacturing company that is engaged in producing plywood products as its main product. This company has waste in the production line, namely in the 4.6 mm Birch product, including shrinkage putty, press mark, tip delemination, bubbles, ripping. Whereas for 18 mm Birch products, among others, press marks, putty shrinkage, concave, overlap, putty face too wide, ripping, waste in the face and delamination of the ends. What you want to achieve in this research is to eliminate the waste of 4.6 mm Birch Products and 18 mm Birch Products found in the Hot Press section in order to fulfill customer demand with the Lean Manufacturing approach. Lean Manufacturing is a systematic approach that eliminates waste and transforms processes. The results of the inspection using the Quality Filter Mapping (QFM) method obtained the largest waste in the Birch 4.6 mm Face 0.5 mm product, namely Failure to Riject by 0.82% and on Birch 18 mm Face 0.28 mm product, namely Failure to Riject by 7.1%. Recommendations for improvement include standard parameters of temperature, press time and pressure.

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