scholarly journals Algorithm to Use Some Specific Lean Manufacturing Methods: Application in an Industrial Production Process

Processes ◽  
2021 ◽  
Vol 9 (4) ◽  
pp. 641
Author(s):  
Ana Cornelia Gavriluţă ◽  
Eduard Laurenţiu Niţu ◽  
Constantin Alin Gavriluţă
Keyword(s):  
Production System ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Evaluation Method ◽  
Production Systems ◽  
Work Processes ◽  
Continuous Increase ◽  
Production Area ◽  
Manufacturing Methods ◽  
Performance Evaluation Method

Lean Manufacturing includes an ensemble of methods to analyze and continuously improve the functioning of manufacturing systems. The research presented in the literature highlights the fact that these methods are, on their own, in a process of continuous improvement as tools, being used in different ways, for different production systems. The paper presents an algorithm that facilitates the choice of the performance evaluation method, and the choice of the method of improvement that needs to be implemented for an efficient analysis and for a continuous increase of the manufacturing system performance. In addition to these, for the JobObservation and 5S methods, chartflows are proposed and specific tools are developed (questionnaires, forms etc.) that are meant to facilitate the implementation and to focus (guide) the user in the direction of improvement for the analyzed process. The algorithm, techniques, and tools developed in this research were used in a case study that took place in a production system “plastic injection”. Thus, a series of important improvements were made in the functioning of the production system, consisting of the reduction of production area, decrease of cycle time, decrease of the number of operators, stabilization, standardization, and securing of the work processes. All this has led to the improvement of several key performance indicators (KPIs) of the production system. The analysis of the investment in the reorganization of the production system in relation to the obtained gains shows a payback of approximately 1 month, proving the efficiency of use in such a form of the Lean Manufacturing methods.

Seru Production System

2021 ◽  
pp. 113-138
Author(s):  
Emre Bilgin Sarı ◽  
Sabri Erdem
Keyword(s):  
Production System ◽  
Mass Production ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Job Shop ◽  
Production Systems ◽  
Cost Effective ◽  
Opportunity To Respond ◽  
Manufacturing Management ◽  
The Impact

Seru production system is a flexible, cost-effective, workforce competence-oriented manufacturing management system that provides the opportunity to respond quickly to customer demand. As in parallel to technology and physical improvements, customer demands are also effective for development of production systems. The impact of change in demand has been seen on changeover from job shop to mass production, flexible, and lean manufacturing systems. Seru production system is more appropriate for targeting work both cost-effectively like mass production and maximum diversification like job shop production. This chapter clarifies the Seru production system and explain its use and benefits in the clothing industry. In the application, a shirt production is illustrated according to the principles of mass production, lean production, and Seru production. Thus, different types of production systems have been benchmarked. There will be potential study areas for proving the efficiency of Seru soon.

Beyond Lean Manufacturing: Developing an Integrated Methodology to Design Effective Manufacturing Systems

2008 ◽  
Author(s):  
Marco Cantamessa ◽  
Francesca Montagna
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Corporate Strategy ◽  
Systems Approach ◽  
Production Systems ◽  
Scientific Basis ◽  
Manufacturing Companies ◽  
Systems Of Systems ◽  
Lean Principles ◽  
Manufacturing Operations

Global competition forces manufacturing companies to operate deep changes in their production systems, involving physical resources, operating procedures and the organization. In this context, the Lean Manufacturing (LM) paradigm is quite popular and lean practice efforts have crossed from the automotive sector into other industries. Most academic contributions to literature concerning LM are on specific aspects of LM, while there is little discussion on the overall implementation of LM. This is despite the fact that lean principles encompass all aspects of manufacturing operations and the need of a systemic approach is clearly shown in practitioner-oriented literature. A number of factors (i.e. cultural, technological and industrial differences) may influence or inhibit the implementation of LM. This paper focuses on some of the critical aspects of LM and analyzes the reason why LM principles are difficult to implement. In particular it suggests that, by formulating a solid scientific basis, the application of LM in industry could become easier and more rigorous, and not only based on past experience. At the same time, the paper suggests that when theory-based tools are used in an isolated way, this carries the risk of not effectively coping with the systemic nature of manufacturing systems. This paper proposes the idea of an innovative methodology able to lead beyond the usual concept of LM, i.e. to adopt its basic principles and systemic perspective, but following a rational and deductive approach that explicitly considers company specific features. The methodology is based on the “Systems of Systems” approach currently being used in the context of complex military initiatives and on the integration of different tools, each focused on specific aspects of the manufacturing system. The paper makes a preliminary attempt to describe how the main aspects of manufacturing systems (resources, quality management systems, production planning and control procedures, etc.) can be represented within the SoS framework and how SoS can support the rational definition of the path leading from corporate strategy to system redesign.

Pull Production Systems

2021 ◽  
pp. 80-112
Author(s):  
Eduardo Guilherme Satolo ◽  
Milena Estanislau Diniz Mansur dos Reis ◽  
Robisom Damasceno Calado
Keyword(s):  
Decision Making ◽  
Hybrid Systems ◽  
Production System ◽  
Lean Manufacturing ◽  
Production Systems ◽  
Pull Production ◽  
Decision Making Processes ◽  
Pull Systems ◽  
Aid Decision ◽  
Pull Production System

This chapter aims to organize knowledge about pull production systems by presenting the underlying concepts of lean manufacturing as for its origin, principles, and relations with PPC. Pull production is one the fundamental principles of lean manufacturing, and its implementation can bring positive impacts. For such a purpose, sequential and mixed supermarket pull systems stand out in which the integration between pull production systems and PPC and its various levels is a main subject of discussion. The JIT model or Kanban method and hybrid systems, such as conwip and lung-drum-string theory, are mechanisms for managing pull production systems. Finally, a pull production system implementation is presented for illustration purposes. At the end of this chapter, it is expected that skills are developed by readers, which are going to assist them in using the tools presented to model production systems and aid decision-making processes.

scholarly journals Manufacturing operational management modeling using interpreted Petri nets

2020 ◽  
Vol 27 (2) ◽  
Author(s):  
Diego Nogueira Guirro ◽  
Osvaldo Luis Asato ◽  
Givanildo Alves dos Santos ◽  
Francisco Yastami Nakamoto
Keyword(s):  
Petri Nets ◽  
Enterprise Resource Planning ◽  
Production System ◽  
Lean Manufacturing ◽  
Industry 4.0 ◽  
Production Systems ◽  
Resource Planning ◽  
Complex Nature ◽  
Manufacturing Execution Systems ◽  
Level 3

Abstract: The dynamics of the interaction between different levels in production system is the study of many research groups to seek a better understanding of the complex nature of such systems to propose an effective and efficiency from rational use of available resources and required inputs. Demand for products increasingly customized by a dynamic and competitive market has reduced considerably the life cycle of such products and flexibility of production processes has become essential for companies. Flexibility is not only one attribute, but a set of attributes that provides the flexibility for production systems. The interactions between the flexible sub-systems are sources of waste and rework, causing high costs in the production process. In this sense, the concept of Lean Manufacturing has promoted a restructuring of some processes of the MES (Manufacturing Execution Systems), responsible for managing the activities of production, integrate data from the ERP (Enterprise Resource Planning) and synchronize production tasks the flow of materials, making them oriented by the demand. One other important aspect in the industrial context is the new future vision promoted by Industry 4.0 paradigm that is envisioned a complete decentralization of control of the production system by autonomous and intelligent devices interconnected by a communication system, that contribute to the global goals of the enterprise. The ANSI/ISA S95 presents a conceptual model that may contribute to the implementation of the industry 4.0 concept. The objective of this study is to present a proposal for modeling of objects in level 3 of the S95 standard using interpreted Petri nets.

Risk Assessment and Reliability Analysis of Subsea Production Systems

2020 ◽  
Author(s):  
Liaqat Ali ◽  
Shan Jin ◽  
Yong Bai
Keyword(s):  
Risk Assessment ◽  
Reliability Analysis ◽  
Deep Water ◽  
Production System ◽  
Evaluation Method ◽  
Oil And Gas ◽  
Production Systems ◽  
Risk Identification ◽  
Subsea Production System ◽  
The Impact

Abstract In past years, offshore oil and gas accidents have often occurred. Environmental hazards have the capability of turning into very difficult to manage in addition with the modern technology limits and lack of a fail-safe operation that can identify, control and terminate the accidents. However, the offshore crude oil also natural gas search and development is expanding to deep-water and moving promptly to the subsea production systems. (SPS). Though, the complicate subsea equipment material besides frequency offshore disasters stimulated the consideration onto the risk analysis of subsea systems. Detection of the impact of deep-water oil and gas reserves in the subsea production system. However, loss of SPSs can contribute to massive industrial failure, severe natural pollution, and indeed serious disasters. Therefore, the reliability analysis and safety of SPS have turned into a dominant consideration. This study addresses on the hazards and risk conditions which must be concentrated in the subsea machinery associated within surface equipments. Furthermore, the risks identification also the risk investigation onto subsea “Xmas tree” system is brought out. An over-all risk avert procedure of subsea “Xmas tree” system is represented, also the reliability evaluation method. Moreover, several recommendations on subsea production maintenance and detection are given in this research. This paper is reviewing the following section, subsea production system, hazards or risk identification, environmental issues, hydrate problems, corrosion problems, safety issues, risk assessment on subsea “Xmas tree”, reliability issues of a subsea system.

scholarly journals Conservation of filtering in manufacturing systems with unreliable machines and finished goods buffers

2006 ◽  
Vol 2006 ◽  
pp. 1-12 ◽  
Author(s):  
Jingshan Li ◽  
E. Enginarlar ◽  
Semyon M. Meerkov
Keyword(s):  
Conservation Law ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Production Systems ◽  
Customer Demand ◽  
Unreliable Machines ◽  
Customer Model ◽  
Necessary And Sufficient ◽  
Insight Into ◽  
Simple Production

This paper addresses the issue of reliable satisfaction of customer demand by unreliable production systems. In the framework of a simple production-storage-customer model, we show that this can be accomplished by using an appropriate level of filtering of production randomness. The filtering is ensured by finished goods buffers (filtering in space) and shipping periods (filtering in time). The following question is considered: how are filtering in space and filtering in time interrelated? As an answer, we show that there exists a conservation law: in lean manufacturing systems, the amount of filtering in space multiplied by the amount of filteringin time (both measured in appropriate dimensionless units) ispractically constant. Along with providing an insight into the nature of manufacturing systems, this law offers a tool for selecting the smallest, that is, lean, finished goods buffering, which is necessary and sufficient to ensure the desired level ofcustomer demand satisfaction.

scholarly journals A novel analysis model for optimization performance of Bernoulli serial production system considering rework processes

2019 ◽  
Vol 234 (1-2) ◽  
pp. 295-309
Author(s):  
Binghai Zhou ◽  
Song Lin
Keyword(s):  
Quality Management ◽  
Production System ◽  
Manufacturing Systems ◽  
Production Systems ◽  
System Modeling ◽  
System Level ◽  
Recent Analysis ◽  
Analysis Model ◽  
Serial Production ◽  
Traditional Approaches

Production system modeling aims to investigate the principles of production procedures and to reveal the relationship between components and systems. Tremendous efforts have been devoted to production system modeling for the serial production system. However, most of the research focuses on the analysis of the systems at the steady state. Due to the emphasis of the quality management, production systems with rework loops are widely used in today’s manufacturing industrials, which the traditional approaches are not applicable to. Since the recent analysis of transients shows significant value and great potential in manufacturing systems, in this article, a new mechanism for rework is introduced based on the principles of quality management and lean production. A novel “Instant-Checking” method is developed to model Bernoulli serial production system considering rework loops. This method overcomes conventional restrictions and limited assumptions, and it extends the problem to systems with complex structures. Meanwhile, the analysis for transients is conducted to demonstrate relationships between component- and system-level characteristics. Finally, numerical experiments are performed to verify the effectiveness of the model.

scholarly journals Impact Assessment on the Economic and Financial Indicators of the Implementation of Lean Management Model

2020 ◽  
Vol 12 (4) ◽  
pp. 49-69
Author(s):  
Fernando Acabado Romana
Keyword(s):  
Performance Evaluation ◽  
Leadership Style ◽  
Lean Manufacturing ◽  
Evaluation Method ◽  
Value Added ◽  
Financial Economic ◽  
Financial Indicators ◽  
Strategic Approach ◽  
Performance Evaluation Method ◽  
The Impact

AbstractObjective: Understand how the increased competitiveness encourages industries to seek solutions in order to maintain or increase their market share, promoting the manufacturing of quality products at reduced costs.Methodology: In this study, an in-company analysis regarding the Lean performance evaluation methods present in the literature as well as already implemented in the industry was performed, focusing on the gaps of present models and needs for future.Findings: New philosophies arise such as the Lean Manufacturing, which is based on continuous improvement, aiming at optimizing the production system, eliminating waste and using fewer resources.Value Added: Based on the results, and with the objective of allowing comprehensive assessment of Lean performance independently by the companies, and the determination of improvement actions, a Lean performance evaluation method was developed in order to understand the impact in financial and economic figures of the case study.Recommendations: Take into account the main concepts of the social sciences, such as Organizational Culture, Leadership Style and Strategic Approach, considering the link with the financial economic performance.

scholarly journals Change management practices to support the implementation of lean production systems: a survey of the scientific literature

2020 ◽  
Vol 27 (2) ◽  
Author(s):  
Isadora Avelar Ferreira ◽  
Fernando Oliveira de Araujo ◽  
Márcia Elisa Soares Echeveste
Keyword(s):  
Literature Review ◽  
Change Management ◽  
Production System ◽  
Lean Manufacturing ◽  
Management Practices ◽  
Production Systems ◽  
Lean Production ◽  
Production Model ◽  
Operational Strategies ◽  
The People

Abstract: The transition from mass production system to lean production system carrier significant changes in operational strategies of industrial organizations. A production model system can engender different reactions by the people involved; some of them can show resistance during the process, ranging from unreserved support to a hidden resistance (even explicit). In order to identify the main practices to support change processes, this study provides a literature review to systematize the main researches related to change management during lean manufacturing implementation. This study aims to provide a systematic literature review covering main researches related to change management and lean manufacturing implementation to identify the main factors that affect the production system change. The research was carried out between October 2016 and January 2018. In methodological terms, literature review was developed by using Scopus and ISI web of Science publications. As a result of this study, 25 papers related to lean manufacturing implementation were identified and 10 factors were consolidated. The most relevant practices of change management were also identified to support lean production system implementation.

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