Applying lean thinking to improve the production process of a traditional medium-size British manufacturing company

Author(s):  
Salman Sigari ◽  
Robin Clark
2018 ◽  
Vol 9 (4) ◽  
pp. 562-578 ◽  
Author(s):  
Saeid Hakimi ◽  
Seyed Mojib Zahraee ◽  
Jafri Mohd Rohani

Purpose This study aims to concentrate on quality improvement in plain yogurt production process at company A through adjusting the factors affecting the acidity of the yogurt and determining the optimal level of these factors. Design/methodology/approach Six Sigma-based framework using define-measure-analyze-improve-control (DMAIC) methodology is adopted through the application of design of experiments tool to focus on customer’s requirements to improve the quality characteristic of plain yogurt production process in dairy products manufacturing company (company A) in Iran. Findings The results showed that incubation time and fat percentage were significant factors on pH values of yogurt and the optimum settings for these factors were defined as 12 h for the incubation time and 1.5 per cent for the fat percentage. Research limitations/implications This study focused solely on the plain yogurt production process in dairy products manufacturing company. Practical implications Simplicity of Six Sigma plays a leading role for enabling any dairy manufacturer to determine the problem and minimize its cause through a systematic approach. Social implications Six Sigma has been considered to be a systematic, powerful technique to continuously improve the processes and develop the new products by using effective analytical and statistical tools and methods. This paper presents a Six Sigma-based framework using DMAIC methodology to improve the quality characteristic of plain yogurt production process in dairy products manufacturing company. Originality/value This study contributes to show a potential area in which Six Sigma DMAIC approach can promote to improve the quality of yogurt production process. This case can prompt managers of the company to apply Six Sigma method to address complicated problems in other processes, where causes particularly are not clear.


2019 ◽  
Vol 27 (3) ◽  
pp. 658-679
Author(s):  
Adefemi Aka ◽  
Abubakar Danladi Isah ◽  
Chukwudum J. Eze ◽  
Owolabi Timileyin

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.


2014 ◽  
Vol 5 (2) ◽  
pp. 456
Author(s):  
Gerry Gerry ◽  
Dyah Budiastuti

PT Cipta Lestari Packindo is a manufacturing company engaging in the manufacture of cardboards. In its operational activities, the company experiences problems like defects or faults in the cardboard production process. Therefore, there’s a need for continuous improvements so that the company won’t suffer either from loss or cost of quality that will appear in the future. To achieve that, the seven tools of quality approach were used in an attempt to repair and reduce the level of errors and the defects in production. Results of this research found there are eight types of the cardboard defection occurred during the productions. By using pareto diagram, research found three major problems that took the biggest roles: pieces that are not aligned with the rotary engine, pieces that are not aligned with the coak engine, and missing in the printing process. In the analysis process of the reduction of defective productions within the three major problems, there are six factors causing the defections: men, machines, methods, measurements, materials, and environments—with men and machines as the biggest contributors. By doing continuous improvements, the level of the defective production will decrease eventually.


Author(s):  
Mukayati Mukayati

  Every company either a service company or a manufacturing company must have the same goal of earning profit. But to achieve that goal is not easy because it is influenced by several factors, and the company must be able to handle these factors. One of the factors that affect the problem is the smoothness of production. The production problem is a very important problem for the company because it is very influential on the profits obtained by the company. If the production process runs smoothly then the company's goal can be achieved, but if the production process does not run smoothly then the company's goals will not be achieved. While the smoothness of the production process itself is influenced by the presence or absence of raw materials will be processed in production.


2016 ◽  
Vol 12 (1) ◽  
pp. 326
Author(s):  
Difana Meilani ◽  
Ryan Eka Saputra

The problem of raw materials is the most fundamental issue for a manufacturing company, because the raw material is something that is very important for a production process. Companies must be able to maintain optimal raw material inventory that the production process can run smoothly so as to achieve the production target set by the company and can meet the demand of consumers. PT. Gunung Pulo Sari is one of the manufacturing company engaged in tire retreading. Here there are two types of main raw material of the tire retreading process is the rubber cold rare steak to cook and cook to cook hot rubber. PT. Gunung Sari Pulo do not meet the criteria of good inventory management. So far the company in order raw materials only based on estimates only. We conducted this study in order PT. Gunung Sari Pulo can manage them inventory system by finding the optimum safety stock, determine the total cost of the minimum size of the buyer to use the dynamic method, and the reorder point. Based on the research that has been done then the obtained value of safety stock is 18 units, the total minimum cost is Rp. Rp. 133 991 672, and reordering time (Reorder point) is 93 units.Keywords: Safety Stock, Dynamic Method, Lot Sizing, Reorder Point


Author(s):  
Adolfo Cano-Carrasco ◽  
María del Carmen Vásquez-Torres ◽  
Elizabeth González-Valenzuela ◽  
Héctor Bellizia- Guzmán

This research analyzes the implementation of the Lean Manufacturing philosophy through a case study in the final assembly line in an electric automotive harness manufacturing company and intends to demonstrate that the current waste from the production process under study will be eliminated through the sustainable application of The Theory of Lean Manufacturing. The methodology used was carried out with the help of the Deming circle: Plan objectives, model line, equipment, training, Execute: design stations, Recognize waste, Establish flow, create mixed lots, calculate Tak-time, Determine matching operations, Determine pull system, Verify: launch and Act: determine verification and monitoring. Subsequently, the programs applied and the activities used for the development of the lean manufacturing philosophy were analyzed. The main contribution is to share the results of a successful case in the implementation of the lean manufacturing philosophy when analyzing the effectiveness of the programs and support activities in its development.


2018 ◽  
Vol 1 (1) ◽  
pp. 217-222
Author(s):  
Michał Molenda ◽  
Aneta Biernot ◽  
Helena Cierna

Abstract The paper deals with the use of Lean Manufacturing tools in improving the production process of car arm rests in a car manufacturing company in Poland. The article describes the original condition of a single production process of assembling ready pieces to produce car arm rests. The original condition was assessed and described with the use of some basic Lean indicators and value stream mapping. The aforementioned tools allowed to assess the process condition and to identify the organizational issues and their sources. It also enabled to reorganize the process and increase its efficiency. The further part of the article describes the results of improvement actions. The process assessment was held and improvements introduced in the first quarter of 2018.


2021 ◽  
Vol 10 (4) ◽  
pp. 215
Author(s):  
NI KADEK DESI PUJA ANTARI ◽  
LUH PUTU IDA HARINI ◽  
NI KETUT TARI TASTRAWATI

The increasing needs for basic materials has resulted in an increased production process of basic materials in a company. CV. Puspa is a manufacturing company engaged in the production of rice, on the production process, CV. Puspa often has a buildup of work so that it requires an alternative production scheduling optimally. This research was conducted to minimize the total time of completion using the Campbell Dudek Smith and Dannenbring method in determining efficient production scheduling. Based on the scheduling sequence obtained, the calculation results of the total completion time using the Campbell Dudek Smith method are less than or equal to the results of calculation using the Dannenbring method. So the Campbell Dudek Smith method is more efficient than the Dannenbring method to be applied to CV. Puspa.


2018 ◽  
Vol 2 (1) ◽  
pp. 13
Author(s):  
Dedi Joko Hermawan

<p>The production process is a series of processes or steps involved in producing a good product in a manufacturing company. To achieve the level of efficiency and effectiveness in the production activity is necessary to note several factors that influence the course of the production process. Design layout and maintenance of production facilities being part of the factor. Where the design layout is a preparation of the layout of production facilities such as machinery and equipment or other equipment used in production activities. While maintenance is an activity to maintain or keep the production facilities to keep them in good condition. The purpose of this study was to determine whether the design layout and maintenance of production facilities have a role in supporting the smooth production process. By using 9 informants, the results of this study indicate that in Probolinggo Clark King Noodle production facility layout design applied adapted to the stages of the production process. While the maintenance of the machines is done routinely every month for oil changes and cleaning and once a year for a replacement battery and dynamo. And it has launched a noodle production process that took place during this time. Thus has proven that the design layout and maintenance of production facilities is instrumental in supporting a smooth production process that takes place within a manufacturing company.</p><p><br />Keywords : Layout Design, Production Facility Maintenance, Production Process</p>


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