Improving the efficiency of energy assessments with application of lean tools—a case study

2019 ◽  
Vol 12 (7) ◽  
pp. 1717-1728
Author(s):  
Raul J. Viera ◽  
Zahra Sardoueinasab ◽  
Jim Lee
Keyword(s):  
Lean Tools

scholarly journals CASE STUDY OF ENERGY CONSERVATION IN INDUSTRY BY APPLICATION OF LEAN TOOLS

2021 ◽  
Vol 5 (12) ◽  
Author(s):  
N.Sujith Prasanna ◽  
Dr.J.Nagesh Kumar
Keyword(s):  
Energy Conservation ◽  
Energy Saving ◽  
Energy Cost ◽  
Energy Use ◽  
Energy Savings ◽  
Sustainable Manufacturing ◽  
Integrated Approach ◽  
Energy Saving Potential ◽  
Lean Tools

Energy cost is significant in many of the manufacturing activities. The efficiency of energy use is quiet low as there are substantial visible and hidden losses. Visible losses can be easily identified and corrective action can be taken. However hidden and indirect losses form a sizeable portion of the losses. Identifying these losses is not easy and requires an integrated approach which includes thorough study of process, operations and their interactions with energy use. Industries across sectors have implemented lean management principles which target various wastes occurring in the plant. This paper discusses case studies which highlight the exploitation of lean tools as a means for unearthing hidden energy saving potential that often go unnoticed. In addition to the energy savings which results in improved profits and competitiveness, the approach also aids the industry to pursue a path of sustainable manufacturing.

scholarly journals APPLICATION OF LEAN TOOLS CASE STUDY IN A TEXTILE COMPANY

2021 ◽  
Vol 3 (1) ◽  
pp. 93-102
Author(s):  
Adelina Baptista ◽  
Luis Abreu ◽  
Elisabeth Brito
Keyword(s):  
Lean Tools

scholarly journals Lean Management “Quick-Wins”: Results of Implementation. A Case Study

2019 ◽  
Vol 23 (3) ◽  
pp. 3 ◽  
Author(s):  
Jorge Rodrigues ◽  
José C.V. De Sá ◽  
Luís P. Ferreira ◽  
Francisco J.G. Silva ◽  
Gilberto Santos
Keyword(s):  
Action Research ◽  
Human Resources ◽  
Research Methodology ◽  
Added Value ◽  
Occupancy Rate ◽  
Implementation Evaluation ◽  
Kurt Lewin ◽  
Lean Tools ◽  
Research Action

<p><strong>Purpose:</strong> This study comprised two main goals. The first goal demonstrates how LT (Lean Tools) allows the highest impact during the implementation phase.The second goal consisted of introducing procedure changes based on the Management of Human Resources through Lean Leadership tool. The target for these two objectives is to achieve an increase of 5% in machine occupancy rate and a reduction of 10% regarding the costs of defective products per hour.</p><p><strong>Methodology/Approach:</strong> The research methodology is a Action-Research/Research-Action developed by Professor Kurt Lewin of MIT that goes through cycles of five stages: Diagnosis; Planning; Implementation; Evaluation, Conclusions.</p><p><strong>Findings:</strong> Regarding the two objectives above mentioned, it was observed an increase of 8.5% in machine occupancy rate and a reduction of 27.9% regarding the costs per hour of defective products. It was created an additional motivation in the employees and very satisfying results in every production.</p><p><strong>Research Limitation/implication:</strong> The study is limited to a Portuguese Small and Medium-sized Enterprise (SME) in the metalworking sector.</p><p><strong>Originality/Value of paper:</strong> Lean tools can be rapidly and easily implemented and quickly understood by the workers. With that implementation, the occupation of the machines has increased and the defects and their costs have decreased, so the added value grows.</p>

scholarly journals Lean Manufacturing Implementation through DMAIC Approach: A Case Study in the Automotive Industry

2021 ◽  
Vol 25 (2) ◽  
pp. 54-77
Author(s):  
Hanane Rifqi ◽  
Abdellah Zamma ◽  
Souad Ben Souda ◽  
Mohamed Hansali
Keyword(s):  
Automotive Industry ◽  
Lean Manufacturing ◽  
Added Value ◽  
Project Duration ◽  
Financial Gain ◽  
Automotive Company ◽  
Single Production ◽  
Lean Tools ◽  
The Right

Purpose: The main objective of this paper is to validate the results of the Lean manufacturing application via the DMAIC concept. This study concerns a case study carried out in an automotive company which aims at improving its flows within the production workshop by pulling the physical flow and minimizing the different wastes.   Methodology/Approach: By conducting a literature review to examine the different frameworks for applying the lean method and to extract case studies related to the DMAIC approach which is missing on the selected articles, only one article that addresses this possibility. Findings: DMAIC has allowed a better structuring of the entire project, choosing the right improvement solutions with the right choice of Lean tools and several advantages that are not valid for other frameworks. This implementation shows a spectacular improvement in the production planning, the fluidity of the flow as well as an important financial gain for the company. Research Limitation/Implication: The project duration was not sufficient to apply other beneficial lean tools as the study was limited only to a single production line. Originality/Value of paper: This article demonstrates the added value of the structured DMAIC approach to lean manufacturing methodology and implementation.

Application of Lean Tools in New Product Development: A Case Study from Precision Metrology Manufacturing

2021 ◽  
pp. 121-139
Author(s):  
Maria Sneha Miranda ◽  
Mukund Nilakantan Janardhanan ◽  
Marina Marinelli ◽  
K. Mathiyazhagan
Keyword(s):  
Product Development ◽  
New Product Development ◽  
New Product ◽  
Lean Tools ◽  
Precision Metrology

scholarly journals Lean Manufacturing Effects in a Serbian Confectionery Company – Case Study

Organizacija ◽  
2014 ◽  
Vol 47 (3) ◽  
pp. 143-152 ◽  
Author(s):  
Ilija Djekic ◽  
Dragan Zivanovic ◽  
Sladjana Dragojlovic ◽  
Radoslava Dragovic
Keyword(s):  
Problem Solving ◽  
Lean Manufacturing ◽  
Visual Control ◽  
Kaizen Events ◽  
Lean Tools ◽  
Five Phases ◽  
Production Company ◽  
Maintenance Process ◽  
Mean Time

AbstractBackground and Purpose: The objective of this paper was to evaluate effects of implementing lean manufacturing in a Serbian confectionery production company during a period of 24 months, emphasizing observed benefits and constrains. Company ‘case study’ is a leading confectionery producer in Serbia with annual production of more than 25,000 t.Methodology/Approach: The research method was case study. The approach in implementing lean manufacturing was structured in five phases, as follows: (i) training, (ii) analysis of lean wastes on one technological line, (iii) choice of lean tools to be implemented in the factory, (iv) implementation of lean tools in production and maintenance, (v) development of continual improvement sector and further deployment of lean tools.Results: Lean manufacturing tools implemented in the production process were visual control and single minute exchange of dies (SMED). Maintenance process implemented 5S with total productive maintenance (TPM) and problem solving sessions being the tools implemented in both processes. During the observed period, results of these tools showed the following: visual control tables initiated 61 improvement memos out of which 39% were fully implemented; a total of 2284 minor problems had been recorded, with over 95% of issues revealed in due time; total SMED time decreased for 7.6%; 19 problem solving sessions were initiated with 58% of solving effectiveness, and the remaining converted to on-going projects. In maintenance 5S improved from 29.9 to 60.3; overall equipment effectiveness (OEE) indicator increased from 87.9% to 92.3%; mean time between failure (MTBF) increased for 16.4%. Conclusion: As a result of all activities, 20 in-house trainings and 2 ‘kaizen’ events including motivational training have been initiated with 54 documents being revised and improved in order to contribute to more efficient processes.

Implementation of Lean Tools in an Automotive Industry for Productivity Enhancement - A Case Study

2017 ◽  
Vol 29 ◽  
pp. 175-185 ◽  
Author(s):  
S. Nallusamy ◽  
M.A. Adil Ahamed
Keyword(s):  
Automotive Industry ◽  
Manufacturing Industry ◽  
Value Added ◽  
Value Stream Mapping ◽  
Lean Principles ◽  
Value Stream ◽  
Whole Process ◽  
Lean Tools ◽  
Cycle Efficiency

Value stream mapping has the reputation of uncovering waste in manufacturing, production and business process. This helps in identifying and removing or streaming value added steps and eliminating non value added steps. In this study the process was analyzed to find an opportunity to drastically reduce the number of actions and to simplify the same. By reducing waste the proportion of value adding time increases in the whole process and the process throughput speed could also be increased. This makes the redesigned process more effective and more efficient. The reengineered process was flow charted in its future state with process steps and information flows re-engineering, simplified and economized. The current layout was analysed to identify and eliminate the non value added activities through lean tools like 5S, VSM and line balancing in a manufacturing industry. From the observed results, it was concluded that the non value added time could be reduced by about 13% while the process cycle efficiency could be increased by about 10%. Virtual simulation was conducted to verify and validate the existing situation as well as to propose the results and the effectiveness of lean principles in a systematic manner with the help of ARENA.

Integration of Simulation and Lean Tools in Effective Production Systems – Case Study

2012 ◽  
Vol 58 (11) ◽  
pp. 642-652 ◽  
Author(s):  
Ranko Božičković ◽  
Milan Radošević ◽  
Ilija Ćosić ◽  
Mirko Soković ◽  
Aleksandar Rikalović
Keyword(s):  
Production Systems ◽  
Lean Tools
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