scholarly journals Case Study on Lean Manufacturing System Implementation in Batch Printing Industry Malaysia

2016 ◽  
Vol 70 ◽  
pp. 05002
Author(s):  
Saihong Tang ◽  
Tanching Ng ◽  
Weijian Chong ◽  
Kahpin Chen
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing System ◽  
Printing Industry ◽  
System Implementation

scholarly journals Lean Manufacturing Case Study with Kanban System Implementation

2013 ◽  
Vol 7 ◽  
pp. 174-180 ◽  
Author(s):  
Nor Azian Abdul Rahman ◽  
Sariwati Mohd Sharif ◽  
Mashitah Mohamed Esa
Keyword(s):  
Lean Manufacturing ◽  
System Implementation ◽  
Kanban System

The Study of Lean Layout in an Automotive Parts Manufacturer

2011 ◽  
Vol 110-116 ◽  
pp. 3947-3951 ◽  
Author(s):  
M. Mat Salleh ◽  
M.Z.M. Zain
Keyword(s):  
Value Chain ◽  
Lean Manufacturing ◽  
Manufacturing System ◽  
Value Added ◽  
Straight Line ◽  
Current Production ◽  
Automotive Parts ◽  
System 2 ◽  
Good Visibility

The term “Lean” was the Japanese model and had been associated with the practice of interpreting the value added activities from those that are wasted (“muda” in Japanese) in an organization and its supply chain [1]. Apart from that, lean was also known as the focus on reducing the non value added (NVA) waste which impedes the flow of the product as it is being transformed in the value chain [2]. Lean manufacturing also means producing only to direct customer orders, creating the need for less on-hand inventory [3]. Lean layout is one of the lean manufacturing tools which have been applied in this automotive parts manufacturer. This tool encourages good visibility and management of the manufacturing system [2]. The U-shape design is incorporated in this case study in order to improve the efficiency of production. In this research, the current production layout is studied and the improvements are conducted by using U-shaped layout which replaced the traditional layout (straight line layout). The results are shown through the figures of the new layout design in the production line.

Assessment of a reconfigurable manufacturing system

2019 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Durga Prasad ◽  
S.C. Jayswal
Keyword(s):  
Lean Manufacturing ◽  
Design Methodology ◽  
Manufacturing System ◽  
Product Family ◽  
Part Family ◽  
Content Type ◽  
Space Cost ◽  
Utilization Cost ◽  
Selection Of

Purpose The purpose of this paper is to develop the methodology which can facilitate the concept of reconfiguration in the manufacturing system. Design/methodology/approach Design methodology includes the calculation of similarity matrix, formation of part family, and selection of part family. ALC algorithm has been used for part family formation and three criteria have been considered for the selection of part family. These criteria are reconfiguration effort, under-utilization cost, and floor space cost. AHP has been used to calculate the weights of criteria and reference ideal method has been used for the selection of alternatives. Findings In the manufacturing system, machines should be grouped on the basis of reconfiguration cost. When the time period is less, light machines and Group 1 machines are added and removed. In the case study, the concept of reconfiguration is useful for families (A, B, C, D). Machines can be reused by adding/removing some modules of machines. The concept of reconfiguration becomes more useful when it is implemented with lean manufacturing. Lean manufacturing techniques Jidoka and Poka-yoke are used to increase the diagnosability of the system. Practical implications Industrial case study has been considered. Social implications Market competition is increasing rapidly and it increases the demand and variety of products, due to which manufacturing enterprises are forced to adapt a manufacturing system which can adjust its capacity and functionality quickly at low cost. To reconfigure manufacturing system from one product/product family to another product/product family, changes can be done in hardware and/or software components in response to sudden changes in the market or in regulatory requirements. Originality/value An integrated approach for reconfiguration has been proposed considering the industrial application. It includes weighted Jaccard function, ALCA, AHP, RIM. The methodology for calculation of reconfiguration effort, under-utilization cost, and floor space cost has been presented for industrial case.

Implementation of Lean Manufacturing Principles in the Process Industry: A Case Study

2015 ◽  
Vol 799-800 ◽  
pp. 1431-1435
Author(s):  
Ali Abd El-Aty ◽  
Ahmad Farooq ◽  
Azza Barakat ◽  
Mohamed Etman
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing System ◽  
Assembly Line ◽  
Raw Materials ◽  
Electronics Industry ◽  
Process Industry ◽  
Industrial Systems ◽  
Cycle Times ◽  
Work In Progress

This research aims at implementing lean manufacturing principles in different industries and re-design the manufacturing system based on the concepts of lean manufacturing by developing a pull-oriented manufacturing system. This research was applied at the assembly line of Sunny Egypt Company for Electronics Industry which related to UNION AIR GROUP at Egypt. LCD 32'' model television was selected from the company's products for improvement. The Results obtained showed that the implementation of lean manufacturing in industrial systems eliminates wastes, increases productivity, profit, improves product’s quality, decreases cycle times, work in progress, inventory, raw materials, costs and number of operators. This research can be useful in developing a more generic approach to design lean environment.

Case Study: The Methodology of Lean Manufacturing Implementation

2013 ◽  
Vol 393 ◽  
pp. 3-8 ◽  
Author(s):  
Nurul Hayati Abdul Halim ◽  
Ahmed Jaffar ◽  
Yusoff Noriah ◽  
Ahmad Adnan Naufal
Keyword(s):  
Continuous Flow ◽  
Lean Manufacturing ◽  
Manufacturing System ◽  
Evaluation Methods ◽  
Time Study ◽  
Step Process ◽  
Assembly Area ◽  
Automotive Assembly ◽  
Significant Achievement

This paper presents a review on the actual implementation of Lean Manufacturing (LM) techniques at a manufacturing area. It focuses on the execution of flow from the beginning until the end of the implementation, types of analyses and tools applied, evaluation methods and how the company benefited from the implementation. The on-site study was conducted at an automotive assembly area, XYZ Sendirian Berhad. LM, using a set of tools, such as time study, single minute exchange of dies (SMED), standardized work, continuous flow manufacturing system (CFMS) and 5-Why analysis were successfully implemented. The flow of implementation activities was designed by referring to Toyotas 8-Step process. The results of this study showed a significant achievement in waste identification and elimination at the case study area. This successfully proves that the Toyota 8-Steps process could work well in any environment, provided the systematic and appropriate methods and tools are used. At the same time, it could also helps to organize and optimize the effectiveness of LM establishment to the company.

Design of pull production control systems using axiomatic design principles

2019 ◽  
Vol 31 (3) ◽  
pp. 620-647
Author(s):  
Ozgur Kabadurmus ◽  
Mehmet Bulent Durmusoglu
Keyword(s):  
Lean Manufacturing ◽  
Design Methodology ◽  
Manufacturing System ◽  
Production Control ◽  
Real Life ◽  
Axiomatic Design ◽  
Content Type ◽  
Production Control System ◽  
Pull Production

Purpose The purpose of this paper is to contribute to the lean manufacturing literature by providing a roadmap for pull production control system (PCS) implementation. Design/methodology/approach Axiomatic Design (AD) methodology is used to develop the proposed pull PCS transformation roadmap. Findings The proposed design methodology is validated in a real-life manufacturing system. The results show that the proposed methodology significantly reduces the design efforts. The methodology effectively helps to choose the most appropriate pull PCS and determine its operational settings with respect to the manufacturing system characteristics. Research limitations/implications This study presents only one case study to test the proposed methodology. In future studies, the validity of the proposed method can be further generalized in different manufacturing sectors by real-life implementations. Practical implications In many real-life lean production projects, companies do not know where to start or how to proceed, which leads to repetitive design efforts and inefficient designs. The developed roadmap of this study minimizes incorrect or imperfect design trials and increases the success of pull production transformation projects. Originality/value The implementation of pull PCS requires extensive design knowledge and expertise. Therefore, many real-life applications fail due to costly and time-consuming trial-and-error-based design efforts. In the literature, there is no comprehensive guideline or roadmap for pull PCS implementation. To address this issue, this study provides a novel holistic roadmap to transform an existing push PCS to pull. The proposed methodology uses AD principles and combines fragmentary studies of the pull production literature.

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