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.

scholarly journals From Lean Manufacturing to Lean Construction: How Principles, Tools, and Techniques Evolved

2021 ◽  
Author(s):  
Sevilay Demirkesen
Keyword(s):  
Construction Industry ◽  
Automotive Industry ◽  
Lean Manufacturing ◽  
Traditional Approach ◽  
Lean Construction ◽  
Work Practices ◽  
Lean Tools ◽  
Low Efficiency ◽  
Tools And Techniques ◽  
Lean Methods

Lean manufacturing first emerged in the automotive industry. However, low productivity and low efficiency in production are major problems for the majority of industries relying on a heavy workforce. Being one of these, the construction industry suffers from low productivity rates along with inefficient work practices. To prevent those, the industry has shifted its focus from the traditional approach to a more innovative one, which is called Lean construction. Lean construction aims to maximize value while minimizing waste. Therefore, it intends to create safer, smoother, and more efficient processes to eliminate waste. This chapter focuses on Lean construction and highlights the generic Lean tools and techniques practiced in the construction industry indicating its historical journey from Lean manufacturing. The chapter aims to raise awareness towards the efficiency of Lean methods in the construction industry with respect to practices observed in manufacturing.

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>

The Implementation of Lean Manufacturing in Malaysian Automotive Industry

2012 ◽  
Vol 576 ◽  
pp. 731-734 ◽  
Author(s):  
S. Ahmad Fakhri ◽  
J. Muhammad Hafiz ◽  
Mohamed Abdul Rahman
Keyword(s):  
Automotive Industry ◽  
Lean Manufacturing ◽  
Manufacturing Environment ◽  
Lean Tools ◽  
Survey Methodologies

The study was conducted to investigate the level of implementation of lean manufacturing (LM) in Malaysian automotive industry. A number of survey methodologies were utilized to ensure reliability of the results of this study. Thirteen areas have been identified as typical workplaces implementing lean manufacturing. The study also investigated the benefits gained and obstacles faced by manufacturers in implementing the system. The frequency and tendency of applying lean tools in manufacturing environment have also been ranked.

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 Evaluation and comparison of a lean production system by using SAE J4000 standard: a case study on the automotive industry in the state of Mexico

2017 ◽  
Vol 14 (4) ◽  
pp. 461
Author(s):  
Lina María Tabares
Keyword(s):  
Data Analysis ◽  
Automotive Industry ◽  
Production System ◽  
Lean Manufacturing ◽  
The State ◽  
Descriptive Statistics ◽  
Production Lines ◽  
Reducing Costs ◽  
Implementation Level

Lean manufacturing (LM) is a management system focused on eliminating waste and activities that do not add value, with the aim of reducing costs and improving the quality and productivity of organizations. LM has been adopted in diverse industries and several countries due to its advantages in cost, flexibility and rapid response (Muslimen et al., 2013). The objective of this investigation is to analyze the implementation level to the Lean System via the SAE J4000 (SAE 1999a) standard carried out among companies of the State of Mexico automotive industry. In addition, this investigation shows the inferential and descriptive statistics data analysis of Mexican companies compared to the automotive industries in Spain and Brazil. Results show that the implementation level of the automotive industry is at 48.4% in the State of Mexico according to the SAE J4000 standard. Moreover, the involvement of suppliers and the use of lean tools in processes are higher in the State of Mexico compared to automotive industries in Spain and Brazil. However, previous studies ranked the State of Mexico at a lower level of LM in contrast with Spain and Brazil production lines.

Cleaner Production Associated with Financial and Environmental Benefits: A Case Study on Automotive Industry

2013 ◽  
Vol 845 ◽  
pp. 873-877 ◽  
Author(s):  
Geraldo C. Oliveira Neto ◽  
Silvio M. Souza ◽  
Elesandro A. Baptista
Keyword(s):  
Production Process ◽  
Automotive Industry ◽  
Raw Materials ◽  
Environmental Issues ◽  
Economic Benefits ◽  
Cleaner Production ◽  
Environmental Benefits ◽  
Financial Gain ◽  
A Company

The Cleaner Production implementation has been expanding significantly in Brazil and there is a strong tendency that companies start to care about environmental issues, such as: input reduction, production process less aggressive to the environment, among other factors inherent to manufacturing process. This paper presents a case study conducted in a company that operates in the field of automotive industry, more specifically in the manufacture of gears for transmissions and diesel engines. The main aims of this research are analyze a machining line focusing on Cleaner Production indicators and evaluate the environmental and economic benefits using the method Material Intensity Factor. The results showed that the company had both environmental benefits and financial gains due to the reduction of raw materials by means of replaced or eliminated material from the production process. The relevant aspect of this study is the possibility of financial gain associated with environmental gains and benefits by means of incremental changes in the production system.

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.

scholarly journals Lean Manufacturing Applications in the Manufacturing Industry

2018 ◽  
Vol 220 ◽  
pp. 02005
Author(s):  
Abdillah Arif Nasution ◽  
Ikhsan Siregar ◽  
Anizar ◽  
Tigor Hamonangan Nasution ◽  
Khalida Syahputri ◽  
...  
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Value Added ◽  
Added Value ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Mapping Analysis ◽  
Manufacturing Applications ◽  
Study Application

This research was conducted in manufacturing industry, so this research is based on case study application. This research serves to reduce waste in the industry when making a product. This study categorizes value-added work and which work has no added value. And it is measurable and has value, so it can be evaluated in the future. Later this will be poured or depicted on a map called Value stream mapping. This is a tool from Lean Manufacturing. Lean manufacturing is useful for analysing and reducing non value-added activities, value stream mapping analysis tools, 5L1H process mapping activities, and 5 why tools. From the results of this study obtained the efficiency of the process cycle and total estimation of the improvement of the lead time. This calculation can be an evaluation material for the company.

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