Assembly line productivity improvement as re-engineered by MOST

2016 ◽  
Vol 65 (7) ◽  
pp. 977-994 ◽  
Author(s):  
A.N. Mustafizul Karim ◽  
Saravanan Tanjong Tuan ◽  
H.M. Emrul Kays
Keyword(s):  
Assembly Line ◽  
Flow Analysis ◽  
Value Added ◽  
Poor Performance ◽  
Hand Tools ◽  
Rear Window ◽  
Productivity Improvement ◽  
Content Type ◽  
Time Standards ◽  
Work Method

Purpose The purpose of this paper is to address and solve operational problems of an automotive industry in reaching production target by adopting Maynard Operation Sequence Technique (MOST) as lean and productivity improvement strategies. Design/methodology/approach In the undertaken case of auto-car rear window assembly line, a recurring production shortfall in fulfilling the daily demand is seemingly due to inappropriate work method. Initial observation of the operations led to suspect certain lapses in initiatives to adopt the time standards, to reduce or eliminate non-value added motions, to design suitable aisle and to assign tasks among workstations in a balanced manner. Subsequently an attempt is made to pinpoint the causes of poor performance and the bottlenecks through process flow analysis and time study by applying MOST. The elemental tasks are closely examined for possible reduction of workstation times by choosing efficient work methods with ergonomic features. Thus appropriate hand tools, jigs and fixture with nominal investment are prescribed to incorporate in the assembly works. The operational changes as steered by the MOST application have enhanced the workflow with a shorter cycle time which led to a substantial increase in productivity. Findings The productivity of the assembly line is increased by more than 29 percent from the earlier capacity through the MOST application which is deemed to meet the current level of demand. Originality/value The adopted framework for recognizing the effectiveness of MOST to expose and rectify the flaws in work methods without much investment is expected to be beneficial for a manufacturer in securing the competitiveness.

Efficiency Enhancement in a Medium Scale Gearbox Manufacturing Company through Different Lean Tools - A Case Study

2018 ◽  
Vol 34 ◽  
pp. 128-138 ◽  
Author(s):  
V. Saravanan ◽  
S. Nallusamy ◽  
Abraham George
Keyword(s):  
Lean Manufacturing ◽  
Processing Time ◽  
Assembly Line ◽  
Value Added ◽  
Value Stream Mapping ◽  
Productivity Improvement ◽  
Medium Scale ◽  
Value Stream ◽  
Manufacturing Company

Productivity is an important parameter for all small and medium scale manufacturing industries. Lean manufacturing emerged as production strategy capable of increasing productivity by identifying and eliminating non value added activities. This article deals with productivity improvement in a pre-assembly line of gearbox manufacturing company with a case study using lean concepts like process flow chart, process Gantt chart and time study. This paper illustrates using a case study on how a value stream mapping has to be carried out in a planet carrier pre-assembly line. Value stream mapping and work standardization are the key tools used in lean manufacturing and lean transformation. It makes the process smoother, helps in reduction of lead time and ultimately increasing the productivity. From the observed results it was found that, the productivity has been increased from 7 pieces to 10 pieces in the first step assembly when the proposed VSM was implemented. The second step processing time was reduced by the execution of proposed value stream mapping with TAKT time of 126 minutes and 165 minutes of processing time for demand of 10 pieces were achieved and the overall processing time has been reduced by about 24%.

Development of a modular garment assembly line simulator

2020 ◽  
Vol 32 (5) ◽  
pp. 645-659
Author(s):  
Eung Tae Kim ◽  
Sungmin Kim
Keyword(s):  
Assembly Line ◽  
Productivity Improvement ◽  
Content Type ◽  
Production Methods ◽  
Final Assembly ◽  
Time Required ◽  
Actual Shape ◽  
Line Design ◽  
The Given ◽  
Optimum Production

PurposeThe purpose of this study is to develop a modular garment assembly line simulator that can be used for various production methods such as traditional mass production or modern small quantity batch production.Design/methodology/approachFor realistic simulation, the actual shape and sewing information of the garment patterns were used. The assembly line consists of process units including the cutter, preprocessor, module assembly, final assembly, finish, and stack units. Any number of units can be arranged and connected to form various layouts. The simulation can be run at an arbitrary speed.FindingsThis system can be used to estimate the time required to process the given order for a specific layout. Therefore, it can be utilized as the basis for optimum production line design.Originality/valueThis system is expected to be utilized by garment manufacturers for obtaining the productivity improvement, production cost reduction, and increased competitiveness.

Redesigning an assembly line through Lean-Kaizen: an Indian case

2014 ◽  
Vol 26 (5) ◽  
pp. 475-498 ◽  
Author(s):  
Anupama Prashar
Keyword(s):  
Assembly Line ◽  
Value Added ◽  
Raw Material ◽  
Value Stream Mapping ◽  
Passenger Cars ◽  
Content Type ◽  
Defect Rate ◽  
Current State ◽  
Kaizen Events ◽  
Component Manufacturing

Purpose – The purpose of this paper is to address the adoption of Lean-Kaizen approach to process improvement by the largest manufacturer of steering systems for passenger car and utility vehicle market in India. The company was facing severe liquidity crunch due to falling customer demand (25 percent lower than forecasted), rising cost of raw material and bank borrowing rates. In order to survive in such stiff scenario, the company systematically deployed Kaizen events and drastically improved their internal efficiency. Design/methodology/approach – The study categorically illustrates the employment of value stream mapping (VSM) to target the areas for Kaizen improvement events. Current state VSM was developed to display the non-value-added activities in the existing assembly process. Future state VSM was proposed. After identifying root cause of wastes using 5 Why, three Kaizen events were proposed. Findings – The current state VSM revealed cumulative inventory of 61 days in the entire process, long distances travelled by subassembly for final assembly (294 meters) and a high defect rate (879 parts per million). After modifying the assembly line using lean strategies, the company reduced its inventory levels by 66 percent, defect rate reduced by 32 percent and achieved other benefits such as reduced equipment, production staff and storage space. These reductions helped the company in saving the working capital and also contributed significantly to its profitability. Originality/value – The study exhibits implementation of Lean-Kaizen approach for redesigning assembly line in an auto component manufacturing unit. The proposed lean strategies are considered to be highly valuable for manufacturer of steering for passenger cars and utility vehicles market.

Optimization of Process Flow in an Assembly Line of Manufacturing Unit through Lean Tools Execution

2018 ◽  
Vol 38 ◽  
pp. 133-143 ◽  
Author(s):  
S. Nallusamy ◽  
V. Saravanan
Keyword(s):  
Lead Time ◽  
Manufacturing Industry ◽  
Assembly Line ◽  
Value Added ◽  
Value Stream Mapping ◽  
Lead Times ◽  
Productivity Improvement ◽  
Value Stream ◽  
Lean Tools ◽  
Lean Methods

The main aim of this study is to achieve the maximum productivity in an assembly line of a valve manufacturing industry through the implementation of different lean tools to minimize the production time. The existing manufacturing data were collected and interpret the information’s for identifying the gaps for productivity improvement. For obtaining the production line performance we shall introduce a solution after finding the problemswhich affects the lead time. In this research, an attempt was made to introduce a new fixture with appropriate lean methods by focusing on value stream mapping, kaizen etc to eliminate different kinds of lead times consuming phases in the overall process. Designing a fixture for the process is also done in Kaizen, in order to exclude the sub operations. After execution of various lean tools the total cycle time was reduced about 10.49 minutes and the productivity was improved about 20% by eliminating all those non value added activities in the operations to meet the customer demand.

scholarly journals Productivity and Spillover effect of merger and acquisitions in Malaysia

2015 ◽  
Vol 38 (3) ◽  
pp. 320-344 ◽  
Author(s):  
Nai Chiek Aik ◽  
M. Kabir Hassan ◽  
Taufiq Hassan ◽  
Shamsher Mohamed
Keyword(s):  
Economic Value ◽  
Spillover Effect ◽  
Value Added ◽  
Spillover Effects ◽  
Productivity Improvement ◽  
Content Type ◽  
Long Run ◽  
Synergistic Gains ◽  
Rival Firms ◽  
Analytical Tools

Purpose – This paper aims to examine the productivity and spillover effect of Malaysian horizontal merger and acquisition (M&A) activities in the long run. Design/methodology/approach – In terms of analytical tools, economic value added (EVA) and data envelopment analysis (DEA) are used. Findings – The results of this study reveal that M&As in the absence of antitrust laws could be driven by managerial self-interest to create market power instead of realizing synergistic gains. Also, in Malaysia, the non-merging rival firms have significantly higher productivity improvement than the control bidder firms, and therefore, this study has identified the spillover effect as a behavior of M&A reaction. Originality/value – This paper differs from previous studies in that it attempts not only to examine the real long-term gains of horizontal M&A activities in Malaysia but also the spillover effects of M&A activities on similar but non-merging firms.

Socioeconomic effects of pension spending: evidence from Spain

2020 ◽  
Vol 47 (5) ◽  
pp. 599-617
Author(s):  
Fernando Bermejo ◽  
Eladio Febrero ◽  
Andre Fernandes Tomon Avelino
Keyword(s):  
Peer Review ◽  
Social Protection ◽  
Pension System ◽  
Decomposition Analysis ◽  
Value Added ◽  
Total Output ◽  
Alternative View ◽  
Input Output ◽  
Structural Decomposition Analysis ◽  
Content Type

PurposeThe purpose of this study is to provide broader understanding of the significant role that the pension system has in the Spanish economy by estimating the sectoral production, employment and income sustained by pensioners' consumption.Design/methodology/approachBased on input–output tables by the World Input–Output Database and consumption data from the Household Budget Survey by the Spanish Statistical Office, a demoeconomic model is applied to quantify the direct impacts, indirect impacts from interindustry links and induced impacts from income–consumption connections over a nine-year period (2006–2014). Then, the factors driving the evolution of total output, employment and value added during such period have been examined by using structural decomposition analysis.FindingsThe growing participation of consumption by pensioner households in final demand had proven crucial during the 2008 crisis to alleviate the negative trend in production and employment derived from the collapse in consumption suffered by the rest of households.Practical implicationsDetermining the underlying factors driving changes in both employment and income during the 2008 crisis can be of interest in political decision-making on the sustainability of the Spanish pension system.Social implicationsThe results of estimating both the employment and income supported by pensioners' consumption reveal the significant stabilizing effect of the public spending on pensions, particularly during the 2008 crisis.Originality/valueThe current Spanish approach of attaining the pension system sustainability by merely reducing social protection costs ignores the adverse consequences of a lower pensioners' demand. This paper addresses an alternative view in which pension spending is not considered a burden on economic growth but rather a means of improving the level of production and employment.Peer reviewThe peer review history for this article is available at: https://publons.com/publon/10.1108/IJSE-01-2019-0047

Utilizing a systematic literature review to develop an integrated framework for information and knowledge management systems

2017 ◽  
Vol 47 (2) ◽  
pp. 250-264 ◽  
Author(s):  
Chulatep Senivongse ◽  
Alex Bennet ◽  
Stefania Mariano
Keyword(s):  
Knowledge Management ◽  
Literature Review ◽  
Systematic Literature Review ◽  
Value Added ◽  
Specific Area ◽  
Management Systems ◽  
Knowledge Management Systems ◽  
Content Type ◽  
Integrated Framework ◽  
Information And Knowledge Management

Purpose The purpose of this paper is to demonstrate the value of using a systematic literature review to develop an integrated framework for information and knowledge management systems. Design/methodology/approach First, the systematic literature review method is introduced, differentiating it from traditional literature reviews in terms of value-added and limitations. Second, this methodology is used in a research application focused on absorptive capacity internal capabilities with regard to the processes of acquisition, assimilation, transformation and exploitation. Third, an integrated framework for information and knowledge management systems is developed from this application. Findings The systematic literature review approach provides a rigor that can assist in reducing researcher bias while simultaneously enabling the definition of a precise scope of review, with a clear explanation of selection criteria with the objective to find and review all the studies that are relevant to the search definitions. As a research method, it effectively supports a qualitative, quantitative or mixed methodology. Research limitations/implications This methodology was applied to one specific area of research. Specific limitations include the availability of articles in subscribed databases and the analytical capabilities of the tools used for text mining and analytics. Originality/value This paper demonstrates the usefulness of the systematic literature review methodology in developing an integrated framework for analysis.

Graduates giving back – a mentoring program for MBA students

2015 ◽  
Vol 4 (3) ◽  
pp. 200-212 ◽  
Author(s):  
Ann Darwin
Keyword(s):  
Higher Education ◽  
South Australia ◽  
Value Added ◽  
Master Of Business Administration ◽  
Mentoring Program ◽  
Education Students ◽  
Content Type ◽  
Mba Students ◽  
A Value ◽  
The University

Purpose – The purpose of this paper is to discuss the challenges and obstacles encountered in the implementation of a mentoring program for Master of Business Administration (MBA) students at the University of South Australia (UniSA) Business School. The paper starts with an exploration into the need for a mentoring program, the trial and subsequent four years of implementation. The paper also explores the network model of mentoring and the reasons why this, rather than a more traditional model, was chosen for the program’s implementation. Design/methodology/approach – This exploratory case study uses data from over 600 students and their alumni mentors over a five-year period to evaluate and improve the program as well as cultivating a critical community of adult learners. Findings – Feedback from students indicates that the mentoring program is regarded by most as a value-added feature of their early learning as it offers support, if and when it is required, from those who have been there before. Research limitations/implications – Results are limited to one institution. However, as research into mentoring for higher education students is thin on the ground, this study contributes to our understanding of the positive impacts of mentoring on student success. Practical implications – This paper emphasizes the importance of business leaders giving back to their alma mater through mentoring current MBA students. It shows how mentoring can support learning and management development. Originality/value – This is an original study which explores ways to increase the learning of higher education students for positive social outcomes.

scholarly journals Overcoming the capital investment hurdle in worker-controlled firms

2019 ◽  
Vol 2 (2) ◽  
pp. 133-150
Author(s):  
Guy Major ◽  
Jonathan Preminger
Keyword(s):  
Capital Investment ◽  
Value Added ◽  
Employee Ownership ◽  
Workplace Democracy ◽  
Equity Investment ◽  
Content Type ◽  
Academic Literature ◽  
Worker Ownership ◽  
Significant Step ◽  
Average Worker

Purpose Both the academic literature and practitioners have long noted the need for an equity investment mechanism for worker-controlled firms that alleviates investor anxieties without undermining internal workplace democracy. The purpose of this paper is to outline one such possible mechanism. Design/methodology/approach The proposal locks together the interests of workers and external investors, via non-voting shares with dividends set by a pre-agreed value-added sharing formula. Each worker is paid a base wage, with the average across the firm being a pre-defined multiple of the national minimum wage. Any additional surplus is split into a number of equal “slices”, with each share receiving one slice as its dividend, and the average worker receiving a pre-agreed number of slices as a bonus. Findings Workers have an incentive to maximise their own incomes, and in so doing, will also automatically maximise the dividends received by investors, obviating the need for the shares to have normal voting rights. Working on this principle of aligned interests, the authors also discuss reinvestment, worker ownership of non-voting shares and possibilities for a secondary share market. The authors show how this proposal will be a significant step in aligning the interests of investors with owner-workers in a democratic, negotiated way that shares both risk and returns, thus making worker-controlled firms more attractive to equity investment. Originality/value In light of the recognised problem of underinvestment in worker-controlled firms and the risk of their degeneration, this paper will interest both academics and practitioners in employee ownership, co-operatives and various forms of workplace democracy.

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