Productivity Improvement By Reducing Waiting Time And Over Production Using Lean Manufacturing Technique

2020 ◽  
Vol 7 (4) ◽  
pp. 20-26
Author(s):  
Ramasubramaniam P
Keyword(s):  
Waiting Time ◽  
Lean Manufacturing ◽  
Productivity Improvement ◽  
Manufacturing Technique

Productivity improvement using lean manufacturing in manufacturing industry of Northern India

2018 ◽  
Vol 67 (8) ◽  
pp. 1394-1415 ◽  
Author(s):  
Jagdeep Singh ◽  
Harwinder Singh ◽  
Gurpreet Singh
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Management Approach ◽  
Successful Implementation ◽  
Productivity Improvement ◽  
Content Type ◽  
Manufacturing Technique ◽  
Northern India ◽  
Lean Tools ◽  
Manufacturing Environments

Purpose The purpose of this paper is to uncover the significance of lean manufacturing technique in manufacturing environments. Design/methodology/approach Lean manufacturing is a management approach focused on incremental improvements in operations. Different lean strategies are being utilized by manufacturing industry to improve the performance of current manufacturing system processes. This study attempts to evaluate the performance of different lean manufacturing tools in the manufacturing industry of northern India. The importance level of different lean tools, important benefits achieved after successful implementation of lean manufacturing approach and benefits occurred after implementation of different lean tools have been identified. A questionnaire survey in the case company has been performed and the most important element of lean manufacturing has been implemented. Findings Results explicitly depict that just-in-time manufacturing is the most important element of lean manufacturing. Results indicate the net savings of rupees 242,208 annually after implementing lean manufacturing technique in a case company. Originality/value The paper demonstrates the practical application of lean technique showing how it can bring real breakthroughs in saving cost in the manufacturing industry.

Analysis on productivity improvement, using lean manufacturing concept

2021 ◽  
Author(s):  
R. Edwin Joseph ◽  
N. Kanya ◽  
K. Bhaskar ◽  
J. Francis Xavier ◽  
S. Sendilvelan ◽  
...  
Keyword(s):  
Lean Manufacturing ◽  
Productivity Improvement

scholarly journals MEMINIMASI PEMBOROSAN DENGAN LEAN MANUFACTURING PADA PROSES PRODUKSI DI PT. IE

2021 ◽  
pp. 1451
Author(s):  
Ahmad Ahmad ◽  
Helena JK ◽  
Andrean Yonathan
Keyword(s):  
Waiting Time ◽  
Cycle Time ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Fault Tree Analysis ◽  
Value Stream Mapping ◽  
Tree Analysis ◽  
Value Stream ◽  
Current State ◽  
Future State

PT. IE is engaged in the business of making Lighting and Lampposts. Based on observations and interviews, there are still some wastes that arise in the flow of the production process, among which there are still many wastes of waiting time, transportation, movement and inventory. These wastes cause the product completion time to be longer and the resulting quality decreases. To eliminate or reduce waste, it is necessary to apply Lean Manufacturing. Lean Manufacturing is a systematic approach to eliminating waste and changing processes by identifying and reducing waste with continuous improvement and striving to create a production flow along the value stream by eliminating all forms of waste and increasing the added value of products to customers. From the Pareto diagram, it is found that transportation waste has the highest percentage of 26.21%, waiting time is 21.38%, motion waste is 19.31% and waste inventories are 15.17%. while the results of the Value Stream Mapping Current State Map mapping obtained a production lead time of 7,680 seconds and a total cycle time of 6,660 seconds and a PCE Current State Map value of 53.09%. Identify the root causes of waste using Fishbone diagrams, 5 Why Analysis, 5W+1H, Fault Tree Analysis and FMEA. After corrective actions have been taken, based on the Value Stream Mapping Future mapping there is a decrease in production lead time to 5,220 seconds and a decrease in total cycle time to 4,860 seconds and an increase in PCE Future State Map to 68.10% so that there is an increase of 15.01% which shows The company's production process has become more Lean.PT. IE bergerak dalam bisnis pembuatan Lighting dan Tiang Lampu. Berdasarkan observasi dan wawancara, masih terdapat beberapa pemborosan (waste) yang timbul di aliran proses produksi di antaranya masih banyak terjadi pemborosan-pemborosan waktu tunggu, transportasi, gerakan dan inventori. Pemborosan-pemborosan tersebut menyebabkan waktu penyelesaian produk menjadi lebih lama dan kualitas yang dihasilkan menurun. Untuk menghilangkan atau mengurangi pemborosan diperlukan adanya penerapan Lean Manufacturing.Lean Manufacturing merupakan pendekatan sistematik untuk mengeliminasi pemborosan dan mengubah proses dengan cara mengidentifikasi dan mengurangi pemborosan dengan perbaikan kontinu dan berupaya untuk menciptakan aliran produksi sepanjang value stream dengan menghilangkan segala bentuk pemborosan serta meningkatkan nilai tambah produk kepada pelanggan. Dari diagram Pareto ditemukan waste transportasi memiliki persentase paling tinggi sebesar 26,21%, waktu tunggu  21,38%, waste motion 19,31% dan waste inventories 15,17%. sedangkan hasil pemetaan Value Stream Mapping Current State Map diperoleh production lead time selama 7.680 detik dan total cycle time selama 6.660 detik serta nilai PCE Current State Map sebesar 53,09%. Identifikasi akar permasalahan pemborosan menggunakan diagram Fishbone, 5 Why Analysis, 5W+1H, Fault Tree Analysis dan FMEA. Setelah dilakukan tindakan–tindakan perbaikan, berdasarkan pemetaan Value Stream Mapping Future ada penurunan production lead time menjadi 5.220 detik dan penurunan total cycle time menjadi 4.860 detik serta ada peningkatan PCE Future State Map menjadi 68,10% sehingga ada peningkatan 15,01% yang menunjukan proses produksi perusahaan telah menjadi lebih Lean.

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%.

Establishing a Just-in-Time and Ubiquitous Output System

2013 ◽  
Vol 5 (3) ◽  
pp. 32-43 ◽  
Author(s):  
Toly Chen ◽  
Michelle Huang
Keyword(s):  
Global Positioning System ◽  
Waiting Time ◽  
Lean Manufacturing ◽  
Just In Time ◽  
Positioning System ◽  
Dijkstra’S Algorithm ◽  
Dijkstra's Algorithm ◽  
Location Aware ◽  
Global Positioning ◽  
Output System

Just-in-time (JIT) is an important topic of lean manufacturing and services, focusing on the reduction of the waiting time. In this study, a JIT ubiquitous output system is established based on the application of a hand-held intelligent device. The system can be regarded as a location aware service (LAS). The JIT ubiquitous output system starts from the detection of the user’s location and speed using the global positioning system (GPS) on the hand-held intelligent device. The detection results and the document to be printed are sent to the server with a reasoning module that searches for the nearby service locations to determine the output location, so that the document can be printed out just before the user reaches the output location, i.e. just in time. To this end, the fuzzy Dijkstra’s algorithm is proposed.

Pendekatan Lean Manufakturing Dalam Pabrik Kelapa Sawit di Aceh Barat

2019 ◽  
Vol 2 (2) ◽  
Author(s):  
Fitriadi
Keyword(s):  
Production Process ◽  
Waiting Time ◽  
Palm Oil ◽  
Lean Manufacturing ◽  
Maintenance Schedule ◽  
Oil Processing ◽  
Machine Maintenance ◽  
Manual Sorting ◽  
Excess Production ◽  
Operational Excellence

Lean Manufacturing adalah cara berkelanjutan untuk mencapai keunggulan operasional pada proses produksi dan dapat diterapkan segala sector operasional di pabrik. Lean Manufacturing adalah salah satu cara yang dapat digunakan perusahaan kelapa sawit untuk melihat tingkat pemborosan pada proses produksi, sehingga mampu menekan biaya atau bahkan dapat mengurangi kegiatan yang tidak diperlukan dalam proses produksi. Tahapan yang dilakukan untuk mengetahui tingkat pemborosan yang terjadi pada pabrik kelapa sawit adalah melakukan identifikasi pemborosan, melakukan pemetaan pemborosan dan memberikan usulan perbaikan untuk mengurangi pemborosan. Pemborosan atau waste pada proses produksi pengolahan kelapa sawit didapatkan empat stasiun kerja yang mengalami pemborosan yaitu stasiun kerja penyortiran, stasiun kerja loading ramp, stasiun kerja sterilizer dan stasiun kerja thressing. Berdasarkan hasil identifikasi didapat enam jenis pemborosanyaitu kelebihan produksi (Over Production), Waktu tunggu (waiting time), Perpindahan (Transportation), Pergerakan (motion), Persediaan (Inventory), dan produk cacat (defect). Rekomendasi perbaikan yang diberikan untuk mengatasi masalah pemborosan tersebut adalah memberikan pelatihan kepada operator, mengurangi penyortiran manual, menambah jumlah operator, pelatihan perawatan mesin secara mandiri oleh operator (autonomus maintenance), membuat jadwal perawatan mesin secara harian (Berkala, adanya informasi petunjuk kerja pada setiap stasiun dan melakukan perhitungan persediaan optimal.   Lean Manufacturing is a sustainable way to achieve operational excellence in the production process and can be applied to all operational sectors in the factory. Lean Manufacturing is one method that can be used by oil palm companies to see the level of waste in the production process, so as to reduce costs or even reduce activities that are not needed in the production process. The step taken to find out the level of waste that occurs in the palm oil mill is to identify waste, carry out waste mapping and provide improvement proposals to reduce waste. Waste or waste in the palm oil processing production process obtained four work stations that experienced waste, namely sorting work stations, loading ramp work stations, sterilizer work stations and pressing work stations. Based on the results of identification obtained six types of waste, namely excess production (Over Production), Waiting time (waiting time), Displacement (Transportation), Movement (motion), Inventory (Inventory), and defective products (defects). Recommendations for improvements given to overcome these waste problems are to provide training to operators, reduce manual sorting, increase the number of operators, train machine maintenance independently by operators (autonomous maintenance), schedule daily maintenance of machines (Periodically, information on work instructions for each station and perform optimal inventory calculations.

Sign in / Sign up

Export Citation Format

Share Document