scholarly journals Scheduling Based Decision Support System Design for Determining the Number of Setup Workers Under SMED Environment

2021 ◽  
Author(s):  
Hatice Nida Civan ◽  
Emre Cevikcan
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Value Added ◽  
Production Method ◽  
Raw Material ◽  
Value Stream Mapping ◽  
Activity Time ◽  
Activity Effect ◽  
Set Up ◽  
Exact Product

Abstract In industrial manufacturing systems, high profit achievement aim considers financial performance under the use of scarce resources and limiting wastes require a systematic approach lean method. Inventory cost, idle time cost, material cost, rework cost rise with large-lot production and work pieces. Achieving economic lot requires setup activity effect. Setup activity effect consists of setup activity time. Setup activity time is production time of previous setup activity exact product to successive setup activity exact product. Manufacturing difficulties of many enterprises push them to demand lean manufacturing tools and develop new ways. Cellular manufacturing, Value stream mapping (VSM), Total productive maintenance (TPM) and Single minute exchange of dies (SMED) are vital lean manufacturing tools to separate Non-value added activities (NVA) and Value added activities (VA), and eliminate wastes. Many studies examined the first four lean manufacturing tool. In this study, scheduling of set-up tasks on SMED environment proposes to examine lead time reduction, lean production method and scheduling setup tasks of setup activity. Continuous improvement encourages setup workers and operators to involve frequent improvement. In the case of yarn processing, setup activity and setup task of machine assigned for jobs to reduce raw material and processing time waste.

Evaluation of Lean Manufacturing Systems Using MADM and Fuzzy TOPSIS

2014 ◽  
Vol 592-594 ◽  
pp. 2628-2638 ◽  
Author(s):  
T.G. Arul ◽  
C. Arumugam ◽  
P. Parthiban
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Value Added ◽  
Fuzzy Topsis ◽  
Global Market ◽  
Triangular Fuzzy Numbers ◽  
Management Philosophy ◽  
Order Preference ◽  
Indian Industries ◽  
Real World Situation

Lean manufacturing is a management philosophy derived from Toyota Production System (TPS) which aims to increase the overall values of the product or service provided to the customer through elimination of non-value added activities. In the era of globalisation, to remain competitive in the global market, many medium and small sized Indian industries adopt lean manufacturing. This paper focuses on implementation of lean manufacturing in Indian MSMEs. To examine the implementation, attributes which influence lean manufacturing are obtained and industries’ performances on these criteria are rated. In this paper, the methodology selected from many of the multi criteria models is the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). In the actual real world situation, because of the unreliable nature of the information gathered, the attributes are often not absolute and are imprecise. These data can be considered as fuzzy and the aim of this paper is to adopt TOPSIS decision making method to problems with fuzzy data. The rating and weights of each data are expressed as triangular fuzzy numbers. These attributes are then normalized and the TOPSIS methodology is carried out to determine the effect of implementing lean manufacturing technique in an industry. The best industry is identified by fuzzy TOPSIS on the basis of performance towards the considered attributes is consistent with results identified by TOPSIS.

scholarly journals Implementation of Lean Manufacturing in a Cement Industry

2021 ◽  
Vol 11 (3) ◽  
pp. 7069-7074
Author(s):  
M. Masmali
Keyword(s):  
Production Line ◽  
Lean Manufacturing ◽  
Production Control ◽  
Value Added ◽  
Cement Industry ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Cement Production ◽  
Work In Process ◽  
Production Processes

The lean manufacturing concept is a systematic minimization of waste and non-value activities in production processes introduced by the Toyota production system. In this research, lean manufacturing is implemented in a cement production line. Value Stream Mapping (VSM) is applied to give a clear picture of the value chain in cement production processes and to highlight the non-value-added in the shop floor. To begin, the existing VSM is constructed based on the information and data gathered during visiting and observing the manufacturing process in the firm. As a result, the excess inventory between workstations was identified as a major waste generation, hence, the proposed VSM conducts further improvement and makes action plans to alleviate the unwanted activities. Then, the takt time to ensure smooth material flow and to avoid any occurring delay or bottleneck in the production line was figured out. The supermarket pull-based production control is suggested to be adopted in the future map. Two pull production strategies are selected in this case. The first is applying the Kanban system to control the level of inventory between workstations. The other is the CONWIP approach to control the amount of work in process to the entire production line. The outcome of the proposed models indicates a decrease of the none-value time from 23 days in the current state to about 4 and 2 days in Kanban and CONWIP systems respectively, so the CONWIP was suggested as most efficient. Some suggestions for further research are also mentioned.

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 Distribution Channel Analysis of Logistics in Supply Chain Management at the Outlet IAP With VSM in Agricultural Sector Industrial Companies

2021 ◽  
Vol 2 (3) ◽  
Author(s):  
Bethriza Hanum
Keyword(s):  
Lean Manufacturing ◽  
Customer Value ◽  
Agricultural Sector ◽  
Selection Process ◽  
Distribution Channel ◽  
Value Added ◽  
Value Stream Mapping ◽  
Order Process ◽  
West Java ◽  
Industrial Companies

PP London Sumatra Indonesia Tbk is a company engaged in agribusiness, which tried to become a retail company in 2016 with Kahuripan Tea products, namely teabags processed from their factories and gardens in the Bandung, West Java area. With marketing areas in West Java and East Java, the focused area is the Jabodetabek area in this research. The problem faced by the company is the delay in the transport order process, which results in delays in the delivery of Kahuripan Tea products to customers. The data on delays used are data from October to December 2019. The problem occurs because there are still many activities that are not value-added which are classified as waste. This research aims to analyze improvements in the transport order process that occurs in the business development and procurement department at PT. PP London Sumatra Indonesia Tbk, with a lean manufacturing approach with the value stream mapping (VSM) method, analyzes the dominant waste in the transport ordering process. Based on the analysis results, there were three improvements, namely the approval process, the price bidding process, and the vendor selection process. The results of the improvement evaluation obtained a decrease in lead time by 560 minutes and an increase in the value of Process Cycle Efficiency by 46%. So, this improvement will increase the practical value in the transport ordering process: that way, PT. PP London Sumatra Indonesia Tbk can increase customer value with fast service time and good quality.

scholarly journals Evaluasi Proses Produksi Country kettle Pada PT PLB Dengan Pendekatan Lean Maufacturing

2021 ◽  
Vol 5 (1) ◽  
pp. 68
Author(s):  
Lina Aulia
Keyword(s):  
Lean Manufacturing ◽  
Value Added ◽  
Value Stream Mapping ◽  
Standard Material ◽  
Value Stream ◽  
Root Cause ◽  
Spinning Process ◽  
Unskilled Workers ◽  
A Company ◽  
Made In

PT PLB (pseudonym) is a company that produces household appliances and kitchen utensils. The country kettle is one type of product made by PT PLB. The productivity of the country kettle production line decreased by 56%. This was due to defective products. The largest percentage of defects in-country kettle products occurred in the spinning process of 40.18%. This study aimed to identify the causes of defects in-country kettle products and how to overcome them by designing improvement proposals. Lean manufacturing principles were used to evaluate the problems that occur. There were three types of lean manufacturing tools used in this study: Value Stream Mapping (VSM) and 5Ways. VSM was used to describe and identify value-added activities, non-value-added activities but necessary, and non-value-added activities so that the production process becomes lean. The root cause analysis was performed using the 5 Whys method. Unskilled workers and non-standard material types between suppliers are the highest contributors to defects in the spinning process. Based on this, this research was focused on improvements made in the spinning process. Proposals for improvements to the causes of the problems found are standardization of work procedures, standardization of supplier specifications, and arrangement of semi-finished goods and/or supplies. Based on the company's results, the proposed standardization of work procedures and arrangement of semi-finished goods and/or supplies may be implemented in the company. Meanwhile, the proposal for selecting suppliers is not feasible due to company limitations

scholarly journals Penerapan Lean Manufacturing Untuk Mengidentifikasi Dan Menurunkan Waste (Studi Kasus CV Tanara Textile)

2019 ◽  
Vol 5 (1) ◽  
pp. 1-7
Author(s):  
Catur Kusbiantoro ◽  
Ellysa Nursanti
Keyword(s):  
Lean Manufacturing ◽  
Lead Time ◽  
Value Added ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Work In Process ◽  
Cycle Efficiency

CV. Tanara Textile merupakan salah satu perusahaan tekstil yang termasuk dalam kelompok industri penyempurnaan kain berupa kain kaos. Pada proses produksi di perusahaan masih ditemukan beberapa waste. Penelitian ini bertujuan untuk mengidentifikasi dan menurunkan waste yang terjadi pada proses produksi maka digunakan pendekatan lean manufacturing. Metode Value Stream Mapping (VSM) digunakan untuk pemetaan aliran produksi dan aliran informasi terhadap suatu produk pada tingkat produksi total, melakukan wawancara untuk pembobotan penyebab 7 waste yang sering terjadi pada proses produksi, VALSAT untuk menganalisa pemborosan dari hasil pembobotan yang selanjutnya melakukan detailed mapping tools, serta analisis FMEA untuk mengetahui penyebab kegagalan prosesyang terjadi di lini produksi lalu menghitung nilai RPN tertinggi. Selanjutnya melakukan usulan perbaikan untuk menurunkan waste unnecessary inventory serta menganalisis perbaikan secara berkelanjutan dengan PDCA. Waste terbesar ada pada Unncessary Inventory sebesar 28,571% faktor penyebabnya adalah penumpukan bahan baku, work in process (WIP), sparepart yang tidak terpakai dan penimbunan pada finished goods Sebelum perbaikan proses produksi 16 hari 9 jam dimana Value Added 6 hari 4 jam dan Lead Time 10 hari 4 jam, setelah perbaikan proses produksi menjadi 14 hari 5 jam dimana Value Added 6 hari 4 jam dan Lead Time 8 hari 1 jam, dengan demikian dapat meningkatkan process cycle efficiency sebesar 17,19% dan menghemat lead time sebesar 2,546% dengan penurunan waste sebesar 8,31%

Implementation of Lean Manufacturing System in Bogie Assembly in Railway Coach Factory

2012 ◽  
Vol 248 ◽  
pp. 511-515 ◽  
Author(s):  
P. Arunagiri ◽  
A. Gnanavelbabu
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Low Cost ◽  
Value Added ◽  
Layout Design ◽  
Design Calculation ◽  
Assembly Shop ◽  
Cost Calculations ◽  
Two Stages

Elimination of the non-value added activities in the bogie assembly shop during bogie assembly process. The various non-value added activities are found in the assembly shop such as excess distance between each assembly stages, excess cost to flow of material from one stage to another stage, waste of time and non-flexibility of shop. These types of non-value added activities occur due to the improper arrangement of bogie assembly stages. Implementation of lean manufacturing systems through layout design by the conversion of existing layout of bogie assembly shop into proposed layout. Analysing the existing layout by using the CRAFT method to find out the best optimized layout .Interchanges are made between each stages that help to correct the present layout. Design calculation are done for various stages .Interchanging of stages of different section are considered by distant matrix and total cost calculations .Various cost of all the pair wise interchanged stages are estimated to find the best low cost interchange. As per the design calculation best interchange between the two stages are considered and that lead to the development of new proposed layout in which all the non-value added activities are eliminated

Application of Lean Tool (Value Stream Mapping) in Minimisation of the Non-Value Added Waste (A Case Study of Tractor Industry)

2011 ◽  
Vol 110-116 ◽  
pp. 2062-2066 ◽  
Author(s):  
Paramdeep Singh ◽  
Harpuneet Singh
Keyword(s):  
Lean Manufacturing ◽  
Lead Time ◽  
Manufacturing System ◽  
Research Work ◽  
Value Added ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Work In Process ◽  
Before And After ◽  
Traditional Manufacturing

Lean manufacturing has been proved to be an effective management philosophy for improving businesses in a competitive market by eliminating non-value added waste and improving in process operations. Value stream mapping is an important tool used to identify the opportunities for various lean techniques. The present research mainly focuses on the description of a model that is developed to contrast the “before” and “after” scenarios in detail in order to obtain the various benefits such as reduced production lead time, lower work in process inventory [1] and proper utilisation of the workforce. The current manufacturing system has been compared with the proposed pull (Kanban) system which shows the benefits of the proposed lean manufacturing system over the existing traditional manufacturing system. The present research work has been carried out at typical tractor industry which shows 50.5% reduction in total lead time in the future state value mapping of the crank case and the number of operators involved in processing of crank case has also been reduced from 22 to 18.

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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