Integration of Waste Assessment Model and Lean Automation to Improve Process Cycle Efficiency in the Automotive Industry

2021 ◽  
Vol 25 (3) ◽  
pp. 48-64
Author(s):  
Setiawan Setiawan ◽  
Indra Setiawan ◽  
Choesnul Jaqin ◽  
Herry Agung Prabowo ◽  
Humiras Hardi Purba
Keyword(s):  
Lean Production ◽  
Global Market ◽  
Assessment Model ◽  
Production Costs ◽  
Added Value ◽  
Manufacturing Companies ◽  
Manufacturing Performance ◽  
Cycle Efficiency ◽  
Assembly Production

Purpose: This study aims to improve Process Cycle Efficiency (PCE) by reducing waste in the assembly production line. This research is a case study conducted in a four-wheel vehicle manufacturing company to create a Lean production system. Methodology/Approach: This study uses the Waste Assessment Model (WAM) and Lean Automation integration methods carried out by 5 expert judgements in the selected four-wheeled vehicle industry. Findings: Based on the WAM method, this study found the biggest waste on the assembly line, namely transportation with a percentage of 20.44%. Improvements made with Lean Automation can increase the value of PCE from 56.76% to 63.62%. Research Limitation/Implication: This research is limited to one model, namely Multi Purpose Vehicle (MPV). This research provides benefits for companies related to waste reduction. For similar companies, this research can be input for manufacturing practitioners in improving manufacturing performance to compete in the global market. This Lean production can reduce manpower which has an impact on saving production costs. Originality/Value of paper: This paper provides added value related to the application of Lean terminology which aims to improve industrial automation-based manufacturing companies.

scholarly journals PERHITUNGAN HARGA POKOK PRODUKSI KERIPIK BAYAM DENGAN METODE FULL COSTING (Studi Kasus Industri Rumah Tangga Keripik Bayam di Kelurahan Mugirejo Kecamatan Sungai Pinang Kota Samarinda) (The Calculation of Production Basic Price of Spinach Chips By Full Costing Method (Case Study at Household Industry of Spinach Chips in Mugirejo Urban Village Sungai Pinang Subcity Samarinda City))

2019 ◽  
Vol 2 (1) ◽  
pp. 35
Author(s):  
DINA LESMANA ◽  
ANGGUN SAPUTRI
Keyword(s):  
Secondary Data ◽  
Production Costs ◽  
Raw Material ◽  
Added Value ◽  
Variable Cost ◽  
Fixed Cost ◽  
Labor Costs ◽  
Urban Village ◽  
Basic Price

The high added value is obtained by agro-industry entrepreneurs increase competition. An effort has made to increase profit  is processing spinach into spinach chips. The purpose of this study was to calculate the production basic price. Research was conducted from August to October 2018 in the home industry spinach chips in Mugirejo Urban Village, Sungai Pinang Subcity, Samarinda City. The data collected was primary and secondary data. Method of data analysis used the full costing method. The result of the study showed that the production costs incurred by home industry of the spinach chips monthly including raw material costs of IDR1,511,000.00; direct labor costs of IDR2,500,000.00; variable cost of factory overhead of Rp755,000.00; and fixed cost of factory overhead of IDR306.583,33. The calculation result of basic price monthly in household industry of spinach chips is IDR5,072,583.33. The monthly sales is IDR16,500,000.00 and the monthly profit obtained by the household industry of spinach chips is IDR11,427,416.67.

scholarly journals Experiences from Implementation of Lean Production: Standardization versus Self-management: A Swedish Case Study

2013 ◽  
Vol 3 (1) ◽  
pp. 31 ◽  
Author(s):  
Margareta Oudhuis ◽  
Stefan Tengblad
Keyword(s):  
Lean Production ◽  
Self Management ◽  
Manufacturing Companies ◽  
Short Cycle ◽  
Problematic Relationship ◽  
Contextual Sensitivity ◽  
The One ◽  
Capacity For Change ◽  
Positive Results

In this article, we discuss important aspects of the perceived problematic relationship between self-management and standardization. The article presents data from three case studies conducted within manufacturing companies in Sweden, where the popularity of lean production has led to a renaissance for short-cycle and standardized assembly work in settings that traditionally have made use of sociotechnical production design. The data suggest that the implementation has not contributed to an increased commitment, smooth operations, and capacity for change and innovation. Despite these not so positive results, it is argued that it is possible to combine self-management principles with lean production and standardization if 1) the implementation of lean is done with a contextual sensitivity, 2) a balance is reached between the use of standards on the one hand and work enrichment on the other, and 3) a feeling of ownership as regards both implementation and production process is upheld among the product on personnel.

scholarly journals An economic feasibility study for the production of apple cider vinegar in Lattakia Governorate – Syria: دراسة الجدوى الاقتصادية لإنتاج خل التفاح في محافظة اللاذقية – سورية

2021 ◽  
Vol 5 (5) ◽  
pp. 125-110
Author(s):  
Nour Ahmad Fadel, Ibrahim Hamdan Saker Nour Ahmad Fadel, Ibrahim Hamdan Saker
Keyword(s):  
Weather Conditions ◽  
Economic Feasibility ◽  
Production Costs ◽  
Added Value ◽  
Market Exchange ◽  
Apple Cider ◽  
Study Approach ◽  
Descriptive Approach ◽  
Bad Weather

The presence of an excess of the apple crop, and the increasing problem of its marketing in case the season is exposed to bad weather conditions, makes the best solution to confront this problem by manufacturing apple cider vinegar, as the apple cider vinegar manufacturing project emerges as an important model for the application of small agricultural projects in Syria, during the next stage, so the aim of the research To study the economic feasibility of a project to manufacture apple cider vinegar in apple- growing areas within Lattakia Governorate in Syria. To achieve the objectives of the research, the descriptive approach and the case study approach were used to study the hypotheses of the study, the most important of which is the existence of an economic feasibility for the manufacture of apple cider vinegar, or the lack of feasibility. The investor is 47.53%, based on production costs, 115.03%, while the profitability coefficient based on the invested capital is 44.49%, and for production costs, 107.67%, and the recovery time of the invested capital is 1.37 years. That is, this project, which achieves an added value, especially for apples that are not suitable for marketing, concludes the research with a number of recommendations, the most important of which is that it should work to encourage agricultural investors to enter this field by providing loans through village banks, development or small projects, and securing a market exchange. for their products, and opening new markets, especially in the field of export.

scholarly journals Innovation in service industry: the role of consultants

2018 ◽  
Vol 5 (4) ◽  
pp. 74-102 ◽  
Author(s):  
Manuela Dias Rezende Pinto ◽  
Irina Saur-Amaral ◽  
Carlos Melo Brito
Keyword(s):  
Service Industry ◽  
Added Value ◽  
Manufacturing Companies ◽  
Study Approach ◽  
Service Companies ◽  
Innovation Intermediaries ◽  
Use Of Technology ◽  
Collaboration Process

Much of the existing literature on innovation intermediaries is focused on manufacturing, and limited scientific knowledge has been developed about the role of intermediaries in services. This paper aims to expand and test an existing framework on the roles and functions of intermediaries in services, focusing specifically on consultancies. Furthermore, it is investigated to what extent services and manufacturing are perceived as different clients, and what represents the added-value of consultancies. Using a case study approach, consultancies´ activities are analysed and compared within services and manufacturing contexts. Findings indicate that while consultancies do not consider manufacturing companies different from service companies, during the collaboration process several differences do exist in terms of their role in these two types of companies, mainly due to different degrees of development of the corresponding innovation strategies and to different perspectives regarding the use of technology. 

scholarly journals Trajectory Optimization of Industrial Robot Arms Using a Newly Elaborated “Whip-Lashing” Method

2020 ◽  
Vol 10 (23) ◽  
pp. 8666
Author(s):  
Rabab Benotsmane ◽  
László Dudás ◽  
György Kovács
Keyword(s):  
Trajectory Optimization ◽  
Industrial Robot ◽  
Industrial Robots ◽  
Added Value ◽  
Robot Arm ◽  
Manufacturing Companies ◽  
Time Saving ◽  
Cycle Times ◽  
Robot Arms

The application of the Industry 4.0′s elements—e.g., industrial robots—has a key role in the efficiency improvement of manufacturing companies. In order to reduce cycle times and increase productivity, the trajectory optimization of robot arms is essential. The purpose of the study is the elaboration of a new “whip-lashing” method, which, based on the motion of a robot arm, is similar to the motion of a whip. It results in achieving the optimized trajectory of the robot arms in order to increase velocity of the robot arm’s parts, thereby minimizing motion cycle times and to utilize the torque of the joints more effectively. The efficiency of the method was confirmed by a case study, which is relating to the trajectory planning of a five-degree-of-freedom RV-2AJ manipulator arm using SolidWorks and MATLAB software applications. The robot was modelled and two trajectories were created: the original path and path investigate the effects of using the whip-lashing induced robot motion. The application of the method’s algorithm resulted in a cycle time saving of 33% compared to the original path of RV-2AJ robot arm. The main added value of the study is the elaboration and implementation of the newly elaborated “whip-lashing” method which results in minimization of torque consumed; furthermore, there was a reduction of cycle times of manipulator arms’ motion, thus increasing the productivity significantly. The efficiency of the new “whip-lashing” method was confirmed by a simulation case study.

scholarly journals PENGARUH KEBIJAKAN DEVIDEN TERHADAP NILAI PERUSAHAAN MANUFAKTUR SEKTOR FOOD AND BEVERAGES

2019 ◽  
Vol 15 (1) ◽  
pp. 126-143
Author(s):  
S Sulistyowati
Keyword(s):  
Low Cost ◽  
Global Market ◽  
P Value ◽  
Manufacturing Companies ◽  
Case Study Method ◽  
High Quality ◽  
Descriptive Research ◽  
Food And Beverages ◽  
Quantitative Descriptive

The prosperity of shareholders can usually be seen from the high value of the company. This means that maximizing shareholder prosperity can be done by maximizing the value of the company. The higher the value of the company, the greater the prosperity that will be received by the shareholders. In the era of globalization, manufacturing companies in the food and beverages sector in Indonesia are trying to produce high-quality goods at low cost in order to increase competitiveness in the domestic market as well as in the global market. Most manufacturing companies in the food and beverages sector are also companies that rely on capital from investors in carrying out their production activities so it is very important for companies to maintain their liquidity health. This type of research is quantitative descriptive research with a case study method. Based on the discussion it can be concluded that dividend policy has a positive and significant effect on the value of manufacturing companies in the food and beverages sector. This is evidenced by the results of the t test value yaituthitung 3.395 and p value 0.001 < 0.05.

Identifying the characteristics for achieving sustainable manufacturing companies

2012 ◽  
Vol 23 (4) ◽  
pp. 426-440 ◽  
Author(s):  
Andrew Thomas ◽  
Mark Francis ◽  
Elwyn John ◽  
Alan Davies
Keyword(s):  
Sustainable Manufacturing ◽  
Production Costs ◽  
Economic Sustainability ◽  
Manufacturing Companies ◽  
Case Study Approach ◽  
Content Type ◽  
Business Sustainability ◽  
Study Approach ◽  
Qualitative Characteristics

PurposeThe purpose of this paper is to identify the qualitative characteristics that can make manufacturing small to medium‐sized enterprises (SMEs) more robust and hence become economically sustainable in this globally competitive environment. The characteristics identified will form the foundations for defining a new manufacturing management perspective to both academics and industrialists.Design/methodology/approachThrough a comprehensive case study approach the authors initially analyse the developmental cycle of the subject company and then identify the key characteristics which enabled the company to become economically sustainable and survive in the changing environment in which it operates. The paper opens with a brief academic analysis of sustainability literature available, before developing the case study.FindingsTraditional business improvement strategies, such as Lean and Agility, which many companies initially follow in an attempt to become more robust and economically stable, allow companies to deliver bottom‐line savings in production terms although their effectiveness depends upon the volume and demand profile of their products. Through the case study outlined in this paper however, a combined approach towards the application of Lean is outlined as a primary means of reducing operating costs alongside the simultaneous implementation of product innovation strategies which allows the company to break into new markets as a means to achieving long‐term economic sustainability and making it more robust to market changes. The development of a business within a business is described as an effective mechanism towards achieving business sustainability.Research limitations/implicationsThe paper proposes a novel approach to achieving economic sustainability within a business and can be of benefit to the wider industrial and academic community. The development of work around a single company has its obvious limitations and it is crucial that further work, with a range of companies in the area of business sustainability, is key to developing a comprehensive set of sustainability characteristics.Practical implicationsThe paper proposes a set of qualitative characteristics for the development of an economically sustainable manufacturing company. The development of a comprehensive case study with a subject company also directs and enables other companies of similar size and style to apply a similar approach and to achieve economic sustainability in an efficient and effective manner, through reducing production costs, minimising company failure and increasing business efficiency and effectiveness.Originality/valueThe development of a set of sustainability characteristics aimed at tackling directly the issues of economic sustainability is proposed and is considered by the authors as one of a kind. The case study approach also provides for a framework towards the implementation of sustainable manufacturing operations within SMEs.

scholarly journals PERHITUNGAN HARGA POKOK PRODUKSI KERIPIK BAYAM DENGAN METODE FULL COSTING (Studi Kasus Industri Rumah Tangga Keripik Bayam di Kelurahan Mugirejo Kecamatan Sungai Pinang Kota Samarinda) (The Calculation of Production Basic Price of Spinach Chips By Full Costing Method (Case Study at Household Industry of Spinach Chips in Mugirejo Urban Village Sungai Pinang Subcity Samarinda City))

2019 ◽  
Vol 2 (1) ◽  
pp. 35
Author(s):  
DINA LESMANA ◽  
ANGGUN SAPUTRI
Keyword(s):  
Secondary Data ◽  
Production Costs ◽  
Raw Material ◽  
Added Value ◽  
Variable Cost ◽  
Fixed Cost ◽  
Labor Costs ◽  
Urban Village ◽  
Basic Price

The high added value is obtained by agro-industry entrepreneurs increase competition. An effort has made to increase profit  is processing spinach into spinach chips. The purpose of this study was to calculate the production basic price. Research was conducted from August to October 2018 in the home industry spinach chips in Mugirejo Urban Village, Sungai Pinang Subcity, Samarinda City. The data collected was primary and secondary data. Method of data analysis used the full costing method. The result of the study showed that the production costs incurred by home industry of the spinach chips monthly including raw material costs of IDR1,511,000.00; direct labor costs of IDR2,500,000.00; variable cost of factory overhead of Rp755,000.00; and fixed cost of factory overhead of IDR306.583,33. The calculation result of basic price monthly in household industry of spinach chips is IDR5,072,583.33. The monthly sales is IDR16,500,000.00 and the monthly profit obtained by the household industry of spinach chips is IDR11,427,416.67.

scholarly journals Implementation of Lean Manufacturing and Kaizen to Improve Productivity in The Production Floor

Jurnal IPTEK ◽  
2020 ◽  
Vol 4 (2) ◽  
Author(s):  
Linda Theresia ◽  
Gadih Ranti ◽  
Ray Kreshna
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Value Added ◽  
Assessment Model ◽  
Added Value ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Current Production ◽  
Engine Maintenance ◽  
Cycle Efficiency

Currently the industry is trying to improve its competitiveness. This makes the manufacturingindustry needs to adapt the Lean-Kaizen concept. Lean-Kaizen means eliminating waste through small improvements made on an ongoing basis. This research takes a case study at PT Inoac Poltechno Indonesia, which is engaged in foam production. The current production target is only 56% of the planned target. Besides that, there are found many defective products and activities that have no added value. Furthermore, a map of the current condition is made to find waste and know the kaizen that will be carried out. Furthermore, a future map was developed with work standardization and Value Stream Mapping to determine activities that have no added value. Calculation of Waste Assessment Model (WAM), shows the biggest waste is defect (26.73%), inventory (15.79%), and waiting (13.35%). This study found that by adding trolley, adding operators, making SOPs, scheduling engine maintenance would make non-value added (NVA) activities decrease from 29.95% to 20.5%. Process Cycle Efficiency increased from 22.31% to 28.25% (thus fulfilling international PCE requirements for the manufacturing industry). Keyword : Lean-Kaizen, productivity, waste

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