scholarly journals Implementation of lean tools and techniques in an ethical papers production industry

2021 ◽  
Vol 5 (2) ◽  
pp. 63-73
Author(s):  
Kukhan S ◽  
Bhuvanesh Kumar M
Keyword(s):  
Lean Manufacturing ◽  
Best Practice ◽  
Continuous Production ◽  
Paper Industry ◽  
Continuous Process ◽  
Research Work ◽  
Manufacturing Industries ◽  
Raw Material ◽  
Lean Tools ◽  
Production Industry

Lean manufacturing (LM) is established as a best practice to improve the performance of manufacturing industries. Not all the manufacturing industries realize the benefits of LM practices specifically continuous process industries. The present research work is intended to study the advantages of implementing LM practices in an ethical paper industry which is a continuous production industry. Presently, the industry suffers with the problems such as lack of productivity, raw material wastes, underutilized resources, and lack of standard practices in the production. Gemba technique is adapted to record the information related to the present manufacturing environment. Based on the current state analysis, the feasible lean tools are selected and implemented such as 5S, Kaizen, and Total Productive Maintenance (TPM). The improvements have been noted as reduced tool change over time, reduced material wastes, effective utilization of resources and provide safety guidelines to workers and operations. The implications of these improvements increased the productivity also.

Technical accounting: sugar extraction and losses

2020 ◽  
pp. 712-721
Author(s):  
Jan Maarten de Bruijn de Bruijn
Keyword(s):  
Process Improvement ◽  
Best Practice ◽  
Continuous Process ◽  
Extraction Yield ◽  
Production Costs ◽  
Raw Material ◽  
Sugar Production ◽  
Cost Leadership ◽  
Sugar Extraction ◽  
White Sugar

The bought sugar in the processed raw material (either beet or cane) comprises a high financial value and may contribute to somewhere around 50% of the white sugar production costs. It is therefore of the utmost importance to minimize sugar losses along the process and produce as much white sugar as possible from the raw material. This paper explains the principle of technical accounting as tool to control sugar extraction and losses in beet sugar manufacture. The sugar mass balance used to calculate the overall sugar extraction yield, as well as several simple calculations proposed for estimating the different sugar losses (like e.g. extraction (diffusion) losses, infection losses, sugar losses in molasses, etc.) in the subsequent process steps will be explained in detail. Proper technical accounting is considered indispensable for continuous process control and process improvement in pursuit of best-practice operation and cost-leadership.

Validity and reliability of lean manufacturing frameworks

2014 ◽  
Vol 5 (4) ◽  
pp. 361-391 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Rambabu Kodali
Keyword(s):  
Frequency Analysis ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Research Work ◽  
Middle Level ◽  
Manufacturing Industries ◽  
Validity And Reliability ◽  
Content Type ◽  
Survey Tool ◽  
Industry Sector

Purpose – The purpose of this paper is to investigate, validity and reliability analysis on existing Lean manufacturing (LM) frameworks when applied to Indian organizations. LM is one of the best manufacturing strategies that are used by manufacturing plant managers to improve manufacturing capabilities. Design/methodology/approach – In the present research work, a questionnaire-based survey was used to examine 35 LM frameworks. The study targeted respondents ranging from top- and middle-level management personnel in Indian manufacturing industry. The sample includes organizations in a variety of industries ranging from automobile, electronics, engineering, process and textile industries products. The survey tool was prepared with team of 12 members i.e. six academicians and six professionals from manufacturing industry environment. The study received 186 responses from various sectors of manufacturing industry, 180 surveys were usable resulting in a response rate of 23.90 per cent. Factor analysis was conducted to check unidimentionality of the framework. Cronbach’s alpha is calculated to find reliability of each framework’s. Lastly, frequency analysis was used to recognize familiar constructs of LM on the chosen framework. Findings – This study has identified that most of the LM frameworks revealed a high level of reliability. When the study has examined further advance about unidimensionality with respect to the construct, i.e. the LM it measures, it confirmed 11 frameworks were revealing unidimensionality. The frequency analysis was evident that a greater part of the constructs has a high mean score and mode. Finally, the research concludes that there is requirement for a novel framework to Indian manufacturing industry to stay in competition with global manufacturing industries. Research limitations/implications – Cross-sectional data from manufacturing industries and India (only one country) is used with sample size restricted to 180 only, and it would be interesting to test these frameworks for more than one industry sector and country. Practical implications – The present work tries to find the suitability of the presented LM frameworks to Indian manufacturing industry sector. The authors hoped that the present research would give the information to the management to execute the suitable LM framework in their firm. Originality/value – The present work tries to find the suitability of the presented LM frameworks to Indian manufacturing industry sector. The authors hoped that the present research would give the information to the management to execute the suitable LM framework in their firm.

scholarly journals Selection the Basic Lean Manufacturing Techniques in Developing the Model for Industry 4.0 in Kosovo Manufacturing Industry

Proceedings ◽  
2020 ◽  
Vol 63 (1) ◽  
pp. 62
Author(s):  
Fatmir Azemi ◽  
Roberto Lujić ◽  
Goran Šimunović ◽  
Daniel Tokody
Keyword(s):  
Literature Review ◽  
Production System ◽  
Lean Manufacturing ◽  
Industry 4.0 ◽  
Manufacturing Industry ◽  
Manufacturing Industries ◽  
Manufacturing Enterprises ◽  
Lean Tools ◽  
Manufacturing Techniques ◽  
Selection Of

Recently, there have been done numerous investigations related to lean manufacturing techniques. However, very little has been reported about the implementation and selection of lean manufacturing in the Kosovo manufacturing industry. This article presents the application of lean tools through Kosovo manufacturing industries and the selection of the most useful lean techniques for developing a model for an innovative smart Kosovo enterprise which is our initiative in the process of preparing Kosovo enterprises for the new age of industry—Industry 4.0. After several visits through Kosovo enterprises, the literature review has noticed that there is no investigation in the selection and implementation of lean techniques and tools in Kosovo enterprises. The purpose was to understand how Kosovo manufacturing enterprises use lean techniques and which are the most useful techniques. Analyses have been done based on interviews and questionnaires. Seven basic lean techniques are selected based on the response from the questionnaire and representing basic lean tools for developing a model of a production system regarding Industry 4.0.

scholarly journals A Literature Review on Implementation of Lean Tools in Industries and Enterprises

2021 ◽  
Vol 9 (VII) ◽  
pp. 247-255
Author(s):  
Prasad V. Valiv
Keyword(s):  
Lean Manufacturing ◽  
Lean Production ◽  
Value Added ◽  
Integrated System ◽  
Manufacturing Industries ◽  
Competitive Environment ◽  
Production Technique ◽  
Severe Problem ◽  
Potential Barriers ◽  
Lean Tools

In today's competitive environment, lean manufacturing becomes necessary across all industries. Lean production is a contemporary production technique of the new millennium. Lean manufacturing has varied synonyms just as lean management, lean production. It provides an extensive approach for decreasing the flow of non-value-added activities. Lean manufacturing is an excellent philosophy to minimize the period amongst client orders and supplies are ready for delivery through eradicating waste. Waste (Muda) is implicit like any process or activity that would not be adding value to the finished product or services. Waste is a severe problem emerging in the manufacturing industries; it causes non-value-added steps which do not expedite outstanding products and services. Waste is minimized with the aid of lean manufacturing. It is an integrated system that entails a minimal buffering cost for services offered and manufactured goods. The present research studies in the domain of Lean are examined to comprehend the execution level of several lean tools, benefits of implementation, and obstacles during the execution of Lean are also scrutinized in the reviewing. Several benefits and potential barriers that occur while implementing the lean culture in various organizations have been identified and listed in this paper.

A Combined VSM and Kaizen Approach for Sustainable Continuous Process Improvement

2019 ◽  
Vol 01 (02) ◽  
Author(s):  
Sadaf Zahoor ◽  
Walid Abdul-Kader ◽  
Hamza Ijaz ◽  
Atif Khan ◽  
Zeeshan Saeed ◽  
...  
Keyword(s):  
Process Improvement ◽  
Lean Manufacturing ◽  
Performance Metrics ◽  
Continuous Process ◽  
Raw Material ◽  
Value Stream Mapping ◽  
Management Approach ◽  
Manufacturing Costs ◽  
Printing Process ◽  
Flexographic Printing

The issues related to setup downtime, raw material waste, and the quality defects are inevitable in the flexographic printing business. To enable sustainable continuous process improvements within the printing process, lean manufacturing methodologies, such as Value Stream Mapping, (VSM), can be a competitive management approach. Therefore, this study explores how the systematic application of VSM in a flexographic printing process can foster further the process improvement when combined with other lean activities, such as, 5S, single minute exchange of die (SMED), and kaizen etc. To assess the contribution of this lean approach, the Overall Equipment Effectiveness, (OEE), and manufacturing costs are taken as performance metrics. The results demonstrate that when integrated with 5-why root cause analysis and kaizen, VSM improved OEE by 24.31% and reduced manufacturing costs from US$0.762 million to US$0.6 million. Hence, the significance of the proposed combined lean approach for continuous improvement is reached.

An application of continuous flow microreactor in the synthesis and extraction of rabeprazole

2021 ◽  
Vol 0 (0) ◽  
Author(s):  
Zhenya Duan ◽  
Yan Wang ◽  
Ling Zhang ◽  
Xing Cao ◽  
Lihua Fu ◽  
...  
Keyword(s):  
Production Efficiency ◽  
Continuous Production ◽  
Continuous Process ◽  
Batch Process ◽  
Raw Material ◽  
Sodium Hypochlorite Solution ◽  
One Pot ◽  
Stomach Acid ◽  
Flow Microreactor ◽  
Rabeprazole Sodium

Abstract The oxidation of rabeprazole sulfide is a key step in the synthesis of rabeprazole, a drug for the treatment of stomach acid-related disorders. The current rabeprazole production process adopts one pot batch process, which has low reaction efficiency and poor stability. A continuous process can greatly improve the production efficiency and solve the above problems. Therefore, the reaction parameters of rabeprazole in microreactor were explored through laboratory experiments to explore the possibility of continuous production of rabeprazole. Rabeprazole sodium was synthesized by using rabeprazole thioether as a raw material and sodium hypochlorite solution as the oxidant. Oxidation, quenching, acid-base regulation and extraction were completed continuously in the microreactor. Rabeprazole solution with a purity of 98.78% (±0.13%) can be obtained continuously in 56 s, whereas intermittent production lasted for at least 2 h. Thus, the microreactor can effectively improve the oxidation synthesis efficiency of rabeprazole, and provide reference for the realization of other reactions in the microreactor.

scholarly journals Experimental tests of PVD AlCrN-coated planer knives on planing Scots pine (Pinus sylvestris L.) under industrial conditions

2021 ◽  
Author(s):  
Krzysztof Nadolny ◽  
Wojciech Kapłonek ◽  
Marzena Sutowska ◽  
Paweł Sutowski ◽  
Piotr Myśliński ◽  
...  
Keyword(s):  
Research Work ◽  
Experimental Tests ◽  
Technical Condition ◽  
Cutting Edge ◽  
Raw Material ◽  
Edge Condition ◽  
Wear Area ◽  
Pine Wood ◽  
Wood Processing ◽  
Machining Operations

AbstractRaw pine wood processing and especially its mechanical processing constitute a significant share among technological operations leading to obtaining a finished product. Stable implementation of machining operations, ensuring long-term repeatable processing results depends on many factors, such as quality and invariability of raw material, technical condition of technological equipment, adopted parameters of work, qualifications and experience of operators, as well as preparation and properties of the machining tools used. It seems that the greatest potential in the search for opportunities to increase the efficiency of machining operations has the modification of machining tools used in it. This paper presents the results of research work aimed at determining how the life of cutting tools used in planing operations of wet pine wood is affected by the application of chromium aluminum nitride (AlCrN) coating to planar industrial planing knives in the process of physical vapour deposition. For this purpose operational tests were carried out under production conditions in a medium-sized wood processing company. The study compares the effective working time, rounding radius, the profile along the knife (size of worn edge displacement, wear area of the cutting edge), selected texture parameters of the planar industrial planing knife rake face and visual analyses of cutting edge condition of AlCrN-coated planar knives and unmodified ones. The obtained experimental results showed the possibility of increasing the life of AlCrN-coated knives up to 154% compared to the results obtained with uncoated ones. The proposed modification of the operational features of the knives does not involve any changes in the technological process of planing, does not require any interference with the machining station nor its parameters, therefore enabling rapid and easy implementation into industrial practice.

Labour Productivity in UK Manufacturing in the 1970s and in the 1980s

1990 ◽  
Vol 132 ◽  
pp. 71-91 ◽  
Author(s):  
Nicholas Oulton
Keyword(s):  
Growth Rate ◽  
Regression Analysis ◽  
Labour Productivity ◽  
Manufacturing Industries ◽  
Raw Material ◽  
Productivity Improvement ◽  
Impact Effect

What accounts for the productivity improvement experienced in manufacturing since 1979? Answers to this question are sought from a regression analysis of 93 manufacturing industries over the period 1971-86. The main findings are that when other influences, such as raw material prices and the shock of the 1980-1 recession, are eliminated, there has been an improvement in the 1980s in the growth rate of productivity whose impact effect averaged 4 per cent per annum. Between a quarter and a half of this is attributable to a decline in the disadvantages of unionisation.

scholarly journals North European Export Industry and the Shadows of Sulphur Directive

2016 ◽  
Vol 17 (1) ◽  
pp. 9-17 ◽  
Author(s):  
Esa Hämäläinen ◽  
Olli-Pekka Hilmola ◽  
Andres Tolli
Keyword(s):  
Paper Industry ◽  
Research Work ◽  
Transportation Cost ◽  
Paper Mill ◽  
Export Industry ◽  
Eu Directive ◽  
Oil Markets ◽  
Regulation Change ◽  
European Export

Abstract EU Directive of MARPOL Annex VI and its economic impact on the Nordic paper industry is theme of this research work. Empirical data for analysis purposes was gained from a large Nordic paper mill that exports bulk products mainly to Europe (70 % of its volume). The study shows that in the end the industry’s location still has an economical effect, and that the location has a distinct impact on competition through rising transportation costs. Environmental regulation continues and fosters long-term upwards trajectory of transportation cost, which has been experienced by the paper mill earlier during years 2001-2009. Sulphur regulation change to cleaner grades of maritime diesel did not turn as heavy cost increase in the 2015, however, possibility to gain cost benefits in rapidly deteriorating oil markets were not reached either. Therefore, in depressed industrial product markets, like paper industry, implications were such that margins of export industry remained low.

Agglomeration Technologies of Processing Powder Wastes

2015 ◽  
Vol 244 ◽  
pp. 121-129
Author(s):  
Marian Peciar ◽  
Roman Fekete ◽  
Peter Peciar
Keyword(s):  
Research Work ◽  
Operating Conditions ◽  
Airborne Particles ◽  
Raw Material ◽  
Production Cycle ◽  
Shear Forces ◽  
Material Resources ◽  
New Type ◽  
Two Phases ◽  
High Technologies

This article deals with the presentation of modern applications for processing powdered, primarily hazardous, waste to an agglomeration form appropriate for subsequent processing by classical methods, for example in the construction, automotive and consumer goods industries. The aim of the research work was to set appropriate operating conditions in order to appreciate currently non-processable wastes resulting from the intensive production of often extremely expensive materials. Technologies which enable returning powder waste back into the primary production cycle were developed and experimentally tested, thus saving raw material resources. When necessary for the fixing of fine airborne particles with a problematic compacting curve (hard to compress, repulsive due to the surface charge) extrusion processes using a patented technology enabling controlled modification of shear forces in the extrusion zone were successfully applied. A new type of axial extruder allows the elimination of the liquid phase and as a result prevents the clogging of the extrusion chamber. In the case of need for granulation of sensitive materials (for example pharmaceuticals not allowing the addition of any kind of agglomerating fluid or reacting strongly in the contact of the two phases), a process of compaction between rolls with different profiled surface was successfully applied. The developed high technologies and the resulting products thus represent a major contribution to environmental protection in the context of not only the work but also the communal environment.

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