scholarly journals Applying Lean Tools and Principles to Improve Sustainability of Waste Management: A Case Study

2018 ◽  
Author(s):  
Nguyen Dat Minh ◽  
Nguyen Danh Nguyen ◽  
Phan Kien Cuong
Keyword(s):  
Waste Management ◽  
Systematic Approach ◽  
Value Added ◽  
Industrial Wastes ◽  
Value Stream Mapping ◽  
Pull System ◽  
Industry Waste ◽  
Value Stream ◽  
Lean Tools

Lean is one of the systematic approach to achieve higher value for organizations through eliminate non-value-added activities. It is an integrated set of tools, techniques, and principles designed to optimize cost, quality and delivery while improving safety. In Vietnam, industry waste management and treatment has become serious issue. The aim of this research is to present the effective of Lean application for industrial wastes collecting and delivery improvement. Through a case study, this paper showed the way of Lean tools and principles applied for wastes management and treatment such as Value Stream Mapping, Pull system, Visual Control, and Andon.... to get benefit on both economic and environment. In addition, the results introduced a good experience for Vietnamese enterprises in cost saving and sustainable development in waste management.

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.

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%.

scholarly journals An Agile System to Enhance Productivity through a Modified Value Stream Mapping Approach in Industry 4.0: A Novel Approach

2021 ◽  
Vol 13 (21) ◽  
pp. 11997
Author(s):  
Varun Tripathi ◽  
Somnath Chattopadhyaya ◽  
Alok Bhadauria ◽  
Shubham Sharma ◽  
Changhe Li ◽  
...  
Keyword(s):  
Industry 4.0 ◽  
Manufacturing Sector ◽  
Value Added ◽  
Value Stream Mapping ◽  
Just In Time ◽  
Value Stream ◽  
Novel Approach ◽  
Decision Making Processes ◽  
Machinery Manufacturing

Worldwide, industries are emphasizing the development of an agile system to sustain higher productivity, which can be applied to ensure improvements in all production conditions in industry 4.0. In the present scenario, several methods are used for improvements in production, such as value stream mapping, kaizen, just in time, Kanban, and total productive maintenance, etc., The objective of the present research article is to produce an agile system to sustain improvements in productivity through a methodology coupled with value stream mapping in industry 4.0. Value stream mapping is a lean-based method and is used for the maximization of productivity by the elimination of non-value-added activities. The proposed methodology has been validated by productivity enhancements achieved in a case study of the earthmoving machinery manufacturing sector. The study establishes that the proposed methodology would encourage industry personnel during decision-making processes, which would lead to improvements in production in industry 4.0.

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.

Optimization of Process Flow in an Assembly Line of Manufacturing Unit through Lean Tools Execution

2018 ◽  
Vol 38 ◽  
pp. 133-143 ◽  
Author(s):  
S. Nallusamy ◽  
V. Saravanan
Keyword(s):  
Lead Time ◽  
Manufacturing Industry ◽  
Assembly Line ◽  
Value Added ◽  
Value Stream Mapping ◽  
Lead Times ◽  
Productivity Improvement ◽  
Value Stream ◽  
Lean Tools ◽  
Lean Methods

The main aim of this study is to achieve the maximum productivity in an assembly line of a valve manufacturing industry through the implementation of different lean tools to minimize the production time. The existing manufacturing data were collected and interpret the information’s for identifying the gaps for productivity improvement. For obtaining the production line performance we shall introduce a solution after finding the problemswhich affects the lead time. In this research, an attempt was made to introduce a new fixture with appropriate lean methods by focusing on value stream mapping, kaizen etc to eliminate different kinds of lead times consuming phases in the overall process. Designing a fixture for the process is also done in Kaizen, in order to exclude the sub operations. After execution of various lean tools the total cycle time was reduced about 10.49 minutes and the productivity was improved about 20% by eliminating all those non value added activities in the operations to meet the customer demand.

scholarly journals VALUE STREAM MAPPING (VSM) BASIC TRAINING TO INCREASE INDUSTRIAL PRODUCTIVITY

ICCD ◽  
2019 ◽  
Vol 2 (1) ◽  
pp. 123-126
Author(s):  
Zulfa Fitri Ikatrinasari ◽  
Kosasih Kosasih ◽  
Nico Alexander Vizano
Keyword(s):  
Information Flow ◽  
Material Flow ◽  
Lean Manufacturing ◽  
Value Added ◽  
Value Stream Mapping ◽  
Basic Training ◽  
Value Stream ◽  
Industrial Productivity ◽  
A Company

Value stream mapping (VSM) is one of the tools in Iean manufacturing that can be used to improve the efficiency of a company. VSM can describe material flow and information flow from upstream to downstream, from suppliers to consumers. VSM can be used to identify waste through sorting each activity into value-added or non-value-added activities. VSM training that begins with providing understanding of the concept of lean manufacturing is expected to increase the ability of workers to improve and enhance the performance of their companies. This training gives good results, seen from the results of discussions and presentations of each group in a given case study

scholarly journals Case Study: Maintenance Proposal of Press Parts Production for Minimize Waste by Lean Manufacturing – Value Stream Mapping (VSM)

INSIST ◽  
2017 ◽  
Vol 2 (1) ◽  
pp. 6
Author(s):  
Dessy Agustina Sari ◽  
Sukanta Sukanta
Keyword(s):  
Lean Manufacturing ◽  
Lead Time ◽  
Value Added ◽  
Value Stream Mapping ◽  
Problem Solution ◽  
Value Stream ◽  
A Value ◽  
Material Transportation ◽  
Schedule Activity

Abstract—Higher competition in businesslike field demanded each company acted as a value creator with progressive fixing performance. One of effort in increasing productivity was reducing waste. Enterprise T have seven type of extravagance were over production, transportation, inventory, over processing, motion waiting and defect. Minimize waste have bond with production time which could increase efficiency on using electricity and decreased lead time. Production process in this company showed non-value added time such as excessively material transportation in picking area and so the workers too much waited for the next schedule activity. This condition caused higher product lead time. Lean manufacturing idea necessary was implemented with using tool Value Stream Mapping – VSM. This strategy would resumed for the company maintenance and the result showed that lacking as much 26,45% of lead time could be a problem solution. Reducing lead time could be higher if the company have applied and played continue improvement.Keywords—lead time, lean manufacturing, value stream mapping.

Analysis Of Non Value Added Activity On Ship Production Process Approach Concept Of Value Stream Mapping Case Study At PT. Dumas Tanjung Perak Shipyard Surabaya

2017 ◽  
Vol 11 (1) ◽  
pp. 23-30
Author(s):  
An Apriyani Tebiary ◽  
I Ketut Suastika ◽  
Buana Ma'ruf
Keyword(s):  
Production Process ◽  
Value Added ◽  
Mapping Method ◽  
Value Stream Mapping ◽  
Quality Cost ◽  
Shipbuilding Industry ◽  
Value Stream ◽  
A Value ◽  
Production Effectiveness

Competition of shipyard industry market in this globalization era encourages companies to realize the importance of improving the effectiveness and efficiency so that, able to compete in terms of quality, cost and on time delivery. Production effectiveness is one effort that must be achieved by a shipbuilding industry to survive amid the competition in seizing market share. Production effectiveness is done with the aim of producing economically, continuously and on time to the customer, so that the company's survival can be guaranteed. This study aims to identify the activities that are classified as waste in the process of ship building at PT. Dumas Tanjung Perak Shipyard Surabaya so as to minimize production time in shipyard industry. The results showed the effectiveness of PT. DUMAS currently reaches 84.96%. In the process of improvement with the application of value stream mapping effectiveness value reached 92%. The conclusion of this research is a value stream mapping method can be applied measuring instrument and can describe the flow of production process in shipyard so that can explain in detail activity that give value added or non value added activity.

An Application of Value Stream Mapping in Ceramic Tile Industry: A Case Study

2015 ◽  
Vol 789-790 ◽  
pp. 1283-1286
Author(s):  
Orapadee Joochim ◽  
Siripong Jungthawan
Keyword(s):  
Ceramic Tile ◽  
Manufacturing Process ◽  
Lean Manufacturing ◽  
Current System ◽  
Value Added ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Product Delivery ◽  
Color Mixing

The purpose of this paper is to increase the productivity of a ceramic tile manufacturing process using lean manufacturing technique. The current system of the ceramic tile manufacturing process has been mapped using Value Stream Mapping (VSM) tool, which is a lean manufacturing tool and the wastages in the current system are identified. Afterwards, future state has been created by using VSM tool, which has enhanced process ration by decreasing maximum possible waste in the manufacturing process. The case study demonstrates how the VSM tool has been used to identify and reduce waste in the manufacturing process by 26%, unnecessary inventory by 8.33% and working time of the color-mixing department by 21.57%. This flexibility enhancement causes 2.67% shorter lead time, 2.70% higher value-added ratio and frequent product delivery leading to more profits.

The Effectiveness of Value Stream Mapping (VSM) as an Improvement Tool for the Manufacturing Operation

2014 ◽  
Vol 575 ◽  
pp. 905-909 ◽  
Author(s):  
Mohd Norzaimi Che Ani ◽  
Mohd Adib Razali ◽  
Kauthar A. Rhaffor
Keyword(s):  
Lean Manufacturing ◽  
Raw Materials ◽  
Value Added ◽  
Handling Time ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Data Problem ◽  
Process Operation ◽  
Manufacturing Techniques

This paper presents the application of the Value Stream Mapping (VSM) as improvements tools at selected case study industry. A VSM process is the transformation of raw materials into finished goods and considered interaction of information, operators, machines and materials. The objectives of this project are to study critical wastes in production line and to recommended new design layout based on Lean Manufacturing techniques. Lean is about performance more with minimized the time, inventory, space, labor, and money. The tool of VSM used in this project successfully achieved its objectives to identify waste and proposing the solution for regarding problems. The lead time was reduced by half, the value added ratio was increased drastically and the cycle time was improved by minimize the handling time. VSM was a magical tool that cans reveals of all the data, problem, process, operation and overall flow of processes to make a certain product.

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