Application of lean manufacturing concept for redesigning facilities layout in Indonesian home-food industry

2019 ◽  
Vol 31 (5) ◽  
pp. 815-830 ◽  
Author(s):  
Nilda Tri Putri ◽  
Lora Seprima Dona
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Food Industry ◽  
Facility Layout ◽  
Added Value ◽  
Actual Condition ◽  
Shop Floor ◽  
Content Type ◽  
Home Food ◽  
The Common

Purpose The purpose of this paper is to redesign the layout of production floor by considering lean manufacturing in order to eliminate the waste and using Block Layout Overview with Layout Planning (BLOCPLAN) algorithm to attain new layout of facilities in Indonesian home-food industry. Design/methodology/approach The common problems that might be appearing in home-food industry, especially in the developing countries like Indonesia are unstandardized production process and unorganized work environment which could produce the waste. One of many solutions to handle this problem is improving the work area (work station) in production floor by rearranging and designing standard operating procedure (SOP) by using lean manufacturing concept. The initial data to minimize the waste is motion time study (data) to identify production standard time. The next step is identifying the common waste(s). Meanwhile, the production floor layout used in this research is designed by using BLOCPLAN algorithm. Findings The recommendation of shop floor facility layout is based on identified waste, which is excess transportation. Subsequently, standard operational procedure (SOP) is developed to support the recommended facility layout as the reference for cookie production process so it can minimize the waste. Research limitations/implications Lean concept is one of method that is widely implemented to reduce the occurrence of defective products and waste that do not provide added value. Based on previous researches, it was found that the concept of lean manufacturing can be applied in various types of service and manufacturing industries, both large companies and small and medium enterprises. Home-food industry competition nowadays is getting intense. This condition makes the stakeholders (of home-food industry, especially in Indonesia) need high performance and productivity to keep their business stable in winning the competition. The new layout can reduce the disadvantages of actual condition. Practical implications This research is useful for small- and medium-sized enterprises (SMEs) in Indonesia especially for home-food industry. The BLOCPLAN layout (as the recommendation) has displacement moment with reduction of 40 percent. Social implications This research believed that it can help SMEs improve their productivity in producing cake and cookies in terms of better layout which can reduce worker movement and standardized working procedure. The design of the production facility layout is a method used to rearrange the production process area so that the distance between processes can be minimized. SOPs was provided as the direction and supervision of workers to work according to standards. Originality/value SOP design can support recommended layout as the reference on making the cake (product) to eliminate wastes, which are motion/movement (alternating in production process flow) and long waiting time due to process delays.

RFID impacts on barriers affecting lean manufacturing

2016 ◽  
Vol 116 (8) ◽  
pp. 1585-1616 ◽  
Author(s):  
Muhammad Zeeshan Rafique ◽  
Mohd Nizam Ab Rahman ◽  
Nizaroyani Saibani ◽  
Norhana Arsad ◽  
Waqar Saadat
Keyword(s):  
Literature Review ◽  
Inventory Control ◽  
Systematic Literature Review ◽  
Lean Manufacturing ◽  
Shop Floor ◽  
Lead Times ◽  
Top Management ◽  
Rfid Technology ◽  
Lean Implementation ◽  
Content Type

Purpose Lean manufacturing is one of the leading paradigms for fast and proficient manufacturing but its proper implementation is a foremost task due to certain barriers affecting lean and can be handled when utilized with RFID technology. With this aspect in view, the purpose of this paper is to enlighten and present a thorough literature study that can show how RFID-based lean manufacturing is helpful for handling barriers affecting lean manufacturing in light of previous literature available. Design/methodology/approach In order to achieve this purpose a systematic literature review is conducted to justify the impacts of RFID technology for handling barriers. The aim of this systematic literature review is to initially find the barriers affecting lean implementation and then to explain the properties of RFID-based lean manufacturing which are highly feasible to handle detected barriers. Findings An interrelation is generated in this study which provides a clear indication that the properties of RFID carry significant effects to handle detected barriers in the operational, managerial and financial regime of manufacturing companies. The detected barriers that affect lean implementation are company’s cultures, top management commitment, poor employee administration, lack of finances, unbalanced inventory control, unstable customer handling and longer lead times. The properties of RFID-based lean manufacturing like operational visibility, inventory control, production control, minimized lead times and the real-time data information (to facilitate top management and employees on shop floor) are extremely helpful to control these barriers. Originality/value The originality of this study is the provision of clarity provided to both academicians and practitioners by citing and utilizing previous research studies which undoubtedly indicates positive impacts of RFID on lean implementation.

A DMAIC Six Sigma approach to quality improvement in the anodising stage of the amplifier production process

2018 ◽  
Vol 35 (9) ◽  
pp. 1868-1880 ◽  
Author(s):  
Pallavi Sharma ◽  
Suresh Chander Malik ◽  
Anshu Gupta ◽  
P.C. Jha
Keyword(s):  
Quality Improvement ◽  
Production Process ◽  
Six Sigma ◽  
Shop Floor ◽  
Manufacturing Firm ◽  
Content Type ◽  
Root Cause ◽  
Six Sigma Methodology ◽  
Six Sigma Approach ◽  
Current Reality

Purpose The purpose of this paper is to study the anodising process of a portable amplifier production process to identify and eliminate the sources of variations, in order to improve the process productivity. Design/methodology/approach The study employs the define-measure-analyse-improve-control (DMAIC) Six Sigma methodology. Within the DMAIC framework various tools of quality management such as SIPOC analysis, cause and effect diagram, current reality tree, etc., are used in different stages. Findings High rejection rate was found to be the main problem leading to lower productivity of the process. Four types of defects were identified as main cause of rejections in the baseline process. Pareto analysis resulted in detection of the top defects, which were then analysed in details to find the root cause of the problem. Further study resulted in finding improvement measures that were discussed with the management before implementation. The process is sampled again to check the improvements, and control measures were established. Practical implications The study provides a framework for implementation of DMAIC Six Sigma methodology for a manufacturing firm. The results presented are based on the data collected from the shop floor. Results and findings of the study were implemented for quality improvement of the process. Originality/value The study is based on an original research conducted with the objective of quality improvement in the anodising process of the production process. Besides presenting an approach to DMAIC Six Sigma methodology, an application of the current reality tree tool for root cause analysis is presented, a tool used limitedly in the Six Sigma studies. The tool finds its uniqueness in its ability to address problems relating multiple factors than isolated factors.

Methodology for acquisition of collective tacit knowledge used in diagnosis of defect cause in industrial processes

VINE ◽  
2015 ◽  
Vol 45 (1) ◽  
pp. 22-45 ◽  
Author(s):  
Cláudio Roberto Rosário ◽  
Liane Mahlmann Kipper ◽  
Rejane Frozza ◽  
Bruna Bueno Mariani
Keyword(s):  
Production Process ◽  
Tacit Knowledge ◽  
Raw Materials ◽  
Industrial Processes ◽  
Shop Floor ◽  
Symbolic Language ◽  
Content Type ◽  
Work Measurement ◽  
Use Of Knowledge ◽  
Quality Tools

Purpose – The purpose of this paper was to build the MACTAK methodology, which aims to transform collective tacit knowledge into the explicit one using knowledge elicitation techniques, associated to quality tools structured by systemography, represent it in a symbolic language and production rules and model it in two expert systems which can assist the investigation of defect causes during the metal packaging production process. Design/methodology/approach – The method applied in the research was classified as exploratory, because a preliminary study was conducted, to better suit the mapping methodology for eliciting collective tacit knowledge, to the reality which was intended to be known. Through studies and the application of the systemography technique, a methodology for the elicitation of collective tacit knowledge has been developed. It suggests a systematic sequence of activities, to map and transform collective tacit knowledge into the explicit one, on the production process which was studied. Findings – The types of tacit knowledge were mapped and became explicit through the application of the methodology proposed. A knowledge management system was created, as such knowledge was validated by other mechanics during their training on the shop-floor, which resulted in a structure of unique and shared knowledge. They became explicit for being stored in a knowledge base and presented to its users through the expert system. It is concluded that the methodology of acquiring collective tacit knowledge helped on the reduction of rework index by standardizing the way used to investigate the cause of the defect, in the studied company. Research limitations/implications – The MACTAK methodology was developed for exclusive use in industrial processes where the following elements are presented: process, method, environment, raw materials, labor work, measurement and machine. In this method, the detection of the problem occurs from statistical data. Practical implications – The methodology began in August 2010, and in October 2011, obtained as a result a reduction in rework cost equivalent to US$17,780.95. Originality/value – The methodology is unique, as it refers to the systematic use of knowledge acquisition techniques and tools of quality, and the methodology has a characteristic of direct application in manufacturing processes. The beneficiaries, in this case, are mechanicals of production and quality inspectors that work at the operation level in the company. For the organizational and tactical level, the beneficiaries are engineers of production.

Application of lean manufacturing tools and techniques for waste reduction in Nigerian bricks production process

2019 ◽  
Vol 27 (3) ◽  
pp. 658-679
Author(s):  
Adefemi Aka ◽  
Abubakar Danladi Isah ◽  
Chukwudum J. Eze ◽  
Owolabi Timileyin
Keyword(s):  
Production Process ◽  
Construction Industry ◽  
Lean Manufacturing ◽  
Mixed Methods Research ◽  
Phenomenological Study ◽  
Waste Reduction ◽  
Lean Thinking ◽  
Content Type ◽  
Study Context ◽  
Tools And Techniques

Purpose Non-value adding activities or wastes in the lean term have been the major challenge of the construction industry. Numerous studies have been conducted to investigate how such wastes can be reduced so as to improve the performance of the construction industry. However, the aspect of bricks production process (BPP) has not been extensively covered. Therefore, the purpose of this paper is to investigate the application of lean manufacturing concepts in BPP with a view to identifying the various wastes in the practice, the causes of these wastes and how such wastes can be reduced. Design/methodology/approach Mixed methods research design was adopted by the researchers where literature review was first conducted to establish the fundamental theories and practice standards of lean manufacturing process. Thereafter, a phenomenological study was carried out in a Shelter Clay and Brick Factory located in Minna, Niger State, Nigeria. The data obtained in the phenomenological study were analyzed through content analysis. These data served as the basis for the validation survey that subsequently followed the phenomenological study. Findings The findings in the study show that poor or inadequate supervision is the main factor responsible for wastes such as excessive drying of bricks, overheating of bricks and re-glazing of bricks in Nigerian BPP. Research limitations/implications The study focused on the various wastes in Nigerian BPP. It also focused on the various lean tools/techniques that can be adopted to reduce the wastes. Aspects such as the percentage of the wastes and their cost implication on the factory were not covered during the study and could be further investigated by prospective researchers. Practical implications The study provides knowledge on how lean thinking can be adopted to reduce wastes in BPP. Such knowledge may be beneficial to the present and prospective bricks producers. This implies that the proposed framework in the study allows producers of bricks to identify gaps in their implementation efforts, focus attention on areas that may require improvements, and access the benefits of lean approach in their factory products. The proposed framework may also be beneficial to the academics. Originality/value This paper first gain originality in the study context to propose for a lean framework that can be adopted to reduce wastes in BPP. Furthermore, the paper has not been previously published and all the information obtained from other sources are duly referenced.

A conceptual examination of Lean, Six Sigma and Lean Six Sigma models for managing waste in manufacturing SMEs

2020 ◽  
Vol 17 (1) ◽  
pp. 20-32 ◽  
Author(s):  
Harsimran Singh Sodhi ◽  
Doordarshi Singh ◽  
Bikram Jit Singh
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lean Six Sigma ◽  
Shop Floor ◽  
Content Type ◽  
Manufactured Products ◽  
Manufacturing Organizations ◽  
Scrap Reduction ◽  
Manufacturing Organization

Purpose The purpose of this paper is to examine and evaluate various Lean, Six Sigma and Lean Six Sigma (LSS) models proposed by various researchers, which have been implemented in manufacturing organizations. Design/methodology/approach The present study has followed three major steps in methodology. In the first step, pooling of various research articles has been done, followed by development of the primary results. At the final step, analysis and development of the LSS model have been performed. Findings This paper evaluated and examined various models of Lean Manufacturing, Six Sigma and LSS and developed an advanced LSS model that can be deployed in any manufacturing organization with the purpose of scrap reduction. Originality/value The findings of this study will assist shop floor managers to implement an LSS model in their organizations, which can effectively reduce the waste and enhance the overall productivity and quality of the manufactured products.

scholarly journals MWO Line Optimization Applying Lean Manufacturing Methodology: PIM Case Study

2019 ◽  
Vol 7 (11) ◽  
pp. 776-787
Author(s):  
Aline Azevedo Eleutério ◽  
Alexandra Priscilla Tregue Costa ◽  
David Barbosa de Alencar ◽  
Antônio Estanislau Sanches
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Added Value ◽  
Minimal Amount ◽  
Profit Margins ◽  
Work In Process ◽  
Quality Tools ◽  
Lean Methods ◽  
Very High

With the increasing competitiveness in the market and the constant development of technologies, today companies are constantly improving, the managers' concern is to achieve maximum process productivity with minimum losses and waste, thus reducing the value to the maximum. aggregate to the product and taking considerable profit margins from sales, so it is of paramount importance to have a lean production process, with well-balanced production times, a minimal amount of work in process and especially a minimal amount of labor , which has very high costs that generates added value directly in the product. In this study was applied the methodology, observation, quantitative and deductive based on theoretical references in order to maximize the efficiency of the production process, through the use of some Lean methods and quality tools as a way of discourse for process improvement also applying process balancing with the primary purpose of reducing the amount of direct labor. Thus the present study presented satisfactory results increasing the efficiency of the microwave oven production line, with the reduction of a direct operator, bringing a leaner and more efficient process.

Lean machine manufacturing at Munjal Showa limited

2014 ◽  
Vol 63 (5) ◽  
pp. 644-664 ◽  
Author(s):  
Shivdasini Singh Amin ◽  
Rakesh Atre ◽  
Ankur Vardia ◽  
Boby Sebastian
Keyword(s):  
Cycle Time ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Low Cost ◽  
Shop Floor ◽  
New Approach ◽  
Content Type ◽  
Indigenous Development ◽  
Depth Study ◽  
Increase Productivity

Purpose – The global manufacturing industry is becoming more competitive. Munjal Showa, a shock absorber manufacturer in India, is using indigenous development of lean machines by incorporating concepts of lean manufacturing and low-cost automation techniques to increase their competitiveness. This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time. The purpose of this paper is to offer an in depth study of how at Munjal Showa Ltd lean machines are being developed and manufactured. This paper explores how a cumbersome machine was transformed into a lean machine. Design/methodology/approach – This paper explores how a cumbersome machine was transformed into a lean machine. Findings – This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time. Research limitations/implications – The paper discusses the process of converting one cumbersome machine to a lean machine. Practical implications – Creativity before capital. In lean, team brainstorming of ideas and solutions is emphasized instead of spending large sums of money on capital expenditures Social implications – The cockpit model eases pressure of incumbents on the shop floor. Originality/value – The concepts espoused in the paper has increased productivity by 3.45 times and reduced costs.

A methodology for applying the shop floor management method for sustaining lean manufacturing tools and philosophies: a study of an automotive company in Brazil

2020 ◽  
Vol 11 (6) ◽  
pp. 1233-1252
Author(s):  
Flávio Gaspar ◽  
Fabiano Leal
Keyword(s):  
Lean Manufacturing ◽  
Southeastern Brazil ◽  
Shop Floor ◽  
Application Process ◽  
Content Type ◽  
Practical Applications ◽  
Implementation Model ◽  
Automotive Company ◽  
Practice Opportunities ◽  
Management Method

Purpose The purpose of this paper is to define a method for sustain lean tools and philosophies on a manufacturing environment. Design/methodology/approach An in-depth action research (AR) methodology procedures applied in two cycles were conducted in an automobile company located in southeastern Brazil. The objective is to test the applicability of the shop floor management (SFM) implementation model as presented by Hanenkamp (2013). Findings The SFM model presented by Hanenkamp (2013) has been outlined, detailed and applied in practice. Opportunities for improvement during the application process of this model were verified by changes in its steps. After developing the AR, the authors have shown that the SFM model, as proposed in this paper, can indeed assist managers in applying and maintaining lean manufacturing practices on the shop floor. Originality/value This paper contributes by aiding in filling the gap between practical applications and the sustainability of lean manufacturing concepts and solutions. Furthermore, the guidelines introduced serve as a benchmark for other companies interested in the topic.

scholarly journals Chasing the golden fleece

2019 ◽  
Vol 24 (3) ◽  
pp. 182-186 ◽  
Author(s):  
Fiona MacVane Phipps
Keyword(s):  
Design Methodology ◽  
Healthcare Management ◽  
Added Value ◽  
Common Theme ◽  
Review Section ◽  
Content Type ◽  
Key Points ◽  
Lean Healthcare ◽  
The Common ◽  
Practical Implications

Purpose The purpose of this paper is to develop a common theme between the six research articles submitted for IJHG 24.3. Design/methodology/approach All articles are read and themes extracted which are used to write a review summarising the key points in each while developing an overarching theme for the issue of IJHG. Other literature supporting the development of this theme is also reviewed and used to contribute insights. Findings The findings consist of the common themes developed. In this issue, the common theme was improving care while saving costs in healthcare and the theme was explored in each article in relation to a lean healthcare management/governance philosophy. Practical implications The review section of IJHG allows readers to gain a quick overview of the content and then select the articles they wish to read in full. Originality/value IJHG is the only journal in the Emerald portfolio with a review section of this kind. Thus it provides added value.

Assessing lean implementation and benefits within Indian automotive component manufacturing SMEs

2020 ◽  
Vol 27 (3) ◽  
pp. 1042-1084 ◽  
Author(s):  
Saumyaranjan Sahoo
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Management Practices ◽  
Manufacturing Sector ◽  
Shop Floor ◽  
Automotive Component ◽  
Content Type ◽  
Study Approach ◽  
The Status ◽  
Component Manufacturing

PurposeThe purpose of this paper is to investigate the status of lean manufacturing in Indian automotive sector, component manufacturing industries in terms of lean adoption, benefits, motivation, and challenges of implementing lean manufacturing practices.Design/methodology/approachThe research objectives were achieved by conducting a qualitative multicase study approach. Fourteen Indian automotive component manufacturing small and medium-sized enterprises (SMEs) were chosen based on their different product offerings as well as differing approaches to the introduction and implementation of lean initiatives. Data were collected through in-depth, semistructured interviews supported by shop-floor observations.FindingsThe findings from the present study suggest that some of the participating automotive component manufacturing SMEs have a relatively good understanding of lean concepts and philosophy. However, there is room for further improvement for most SMEs. Major top five lean practices being implemented were found to be cellular manufacturing, total productive maintenance, 5S, work standardization, and quality management practices. Also, leadership and organizational culture were found to be crucial factors for the success of lean manufacturing.Research limitations/implicationsThe fact that the data collected for the research study is based on subjective business evidence obtained from company representatives comprises the main limitation of the present study. So, the results should be considered with caution, as far as the lean adoption in Indian automotive component manufacturing sector is concerned.Practical implicationsBased on the present study, suggestions can be made regarding the successful adoption of lean principles, not only for the participating SMEs but also for the whole of the automotive component manufacturing sector. More specifically, by determining the strength and weakness of automotive component manufacturing SME's effort to adopt lean, suitable managerial initiatives can be undertaken by these companies as well as the whole sector to fully adopt lean and derive the respective benefits.Originality/valueThis paper explores the status of lean adoption in Indian automotive component manufacturing SMEs. Considering the unique characteristics of the automotive component manufacturing industry, the present research would be helpful for making strategies to implement lean in automotive component manufacturing industry setups.

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