scholarly journals Implementación de la manufactura esbelta en una línea de arneses eléctricos automotrices

2019 ◽  
pp. 21-29
Author(s):  
Adolfo Cano-Carrasco ◽  
María del Carmen Vásquez-Torres ◽  
Elizabeth González-Valenzuela ◽  
Héctor Bellizia- Guzmán
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Assembly Line ◽  
Pull System ◽  
Final Assembly ◽  
Successful Case ◽  
Manufacturing Company

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.

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 Implementation of a standard work routine using Lean Manufacturing tools: A case Study

2021 ◽  
Vol 28 (1) ◽  
Author(s):  
Diego Michael Cornelius dos Santos ◽  
Bruna Karine dos Santos ◽  
César Gabriel dos Santos
Keyword(s):  
Continuous Improvement ◽  
Lean Manufacturing ◽  
Assembly Line ◽  
Real Data ◽  
Production Methods ◽  
Standard Work ◽  
Technological Advances ◽  
Work Routine ◽  
Constant Improvement

Abstract: Due to technological advances, trade politicies and society's consumption patterns, competitiveness among companies has increased considerably, requiring practices that provide a constant improvement in production indicators and product quality. In this context, the use of Toyota Production System tools, also known as Lean Manufacturing, have a fundamental role in the elimination of waste and continuous improvement of industrial production levels. Thus, this work aims to implement a standardized work routine among employees working in a market of parts in an Agricultural Machinery industry, which lacks production methods. To represent this situation, real data were used, which correspond to the needs of the assembly line, and which served as the basis for the analysis and implementation of a new work routine. The results obtained enabled the creation of a standardized work routine, which was obtained by balancing activities between operators and eliminating activities that did not add value to the product.

scholarly journals Case study of lean manufacturing application in a die casting manufacturing company

2015 ◽  
Author(s):  
Ng Tan Ching ◽  
Clarence Chan Kok Hoe ◽  
Tang Sai Hong ◽  
Morteza Ghobakhloo ◽  
Chen Kah Pin
Keyword(s):  
Lean Manufacturing ◽  
Die Casting ◽  
Manufacturing Company

scholarly journals A roadmap for improving the manifacture of automotive heat exchangers through value stream mapping

2019 ◽  
Author(s):  
◽  
Kate Lusiba
Keyword(s):  
Production Process ◽  
Heat Exchangers ◽  
Line Balancing ◽  
Value Stream Mapping ◽  
Automotive Manufacturing ◽  
Value Stream ◽  
Final Assembly ◽  
Work In Process ◽  
Value Stream Map

Lean manufacturing is an optimum approach for the reduction and elimination of waste within an organization. The case study company is based in South Africa and produces heat exchangers through main processes or fractals, which include pre-assembly, core building, brazing and final assembly. A walk through the plant showed that there was a large amount of inventory awaiting final assembly and that the brazing furnace often waited for material from core building. This was an indication that there could be an imbalance between the three fractals in terms of cycle time. Thus, the aim of this study was to improve the manufacturing processes for heat exchangers at the automotive manufacturing company through the deployment of value stream mapping, subsequent line balancing and developing a roadmap for reduction of waste. The case study research strategy was adopted for the study since it provided an in-depth view of phenomena. The first objective was to outline the production flow for the manufacture of automotive heat exchanger parts. The method used was a walk through the plant and observations were made to gain an understanding of the production steps from logistics production planning to shipping of the finished goods, and subsequently to a mapping-out of the production process flow was undertaken. The results showed that there was a large amount of inventory awaiting final assembly and that the brazing furnace often waited for material from core building. It was concluded that there was need to conduct a detailed process analysis to identify sources of waste. The second objective was to conduct value stream mapping for assessing the value- and non-value-adding activities in the manufacture of automotive heat exchangers components. A value stream map was developed through walking to Gemba and mapping out the production process, collecting data and pinpointing waste activities or areas to be improved. The kaizen flashes from the value stream map also revealed that operators were not fully utilizing the capacity of the bottleneck workstations. It was concluded that two instead of one planning points, and inefficiency at assembly were root causes of the high work-in-process level. The third objective was to conduct a line balancing analysis for the three production fractals. The method used was a Pareto analysis for evaluating the products, analysing the product mix and line balancing analysis of the production line. The results revealed that the furnace was run on two shifts while the subsequent assembly and preceding core building were running on three shifts causing a work-in-process build-up, thereby resulting in line imbalance. It was concluded that it was imperative to change the scheduling approach, and adopt one that prioritised and spread the cores that had relatively short cycle times, and also reduce downtime, change-over time as well as additional time for scrap and defects, and a future-state balance chart revealed that the fractals imbalance had been reduced. The fourth objective was to develop a roadmap for reduction of waste in the manufacture of car heat exchangers components. The method used was to develop proposals and assess the feasibility and cost implications of implementing each option. Recommendations were made for continuous process improvement and a roadmap for reduction of waste was proposed. In order to improve the output of assembly, training for the operators was recommended since it would also enable the removal of the second planning point at assembly. Further research could also be conducted to develop an optimal scheduling algorithm for allocation of products to work centres to ensure high utilization of work centres and reduce work-in-process inventory.

scholarly journals Applying Lean Manufacturing in the Production Process of Rolling Doors: A Case Study

2020 ◽  
Vol 13 (7) ◽  
pp. 1774-1781
Author(s):  
Leandro L. Lorente Leyva ◽  
Mishell A. Yerovi Huaca ◽  
Yakcleem Montero Santos ◽  
Ramiro V. Saraguro Piarpuezan ◽  
Israel D. Herrera Granda ◽  
...  
Keyword(s):  
Production Process ◽  
Lean Manufacturing

Simulation-Based Comparison of Pull-Push Systems in Motorcycle Assembly Line

2012 ◽  
Vol 241-244 ◽  
pp. 1507-1513
Author(s):  
Umchid Sutee ◽  
Prasad K.D.V. Yarlagadda
Keyword(s):  
Assembly Line ◽  
Assembly Line Balancing ◽  
Influential Factors ◽  
Simulation Software ◽  
Process Time ◽  
Pull System ◽  
Work In Process ◽  
Assembly Line Balancing Problem ◽  
Systems Simulation

To investigate the effects of adopting a pull system in assembly lines in contrast to a push system, simulation software called “ARENA” is used as a tool in order to present numerical results from both systems. Simulation scenarios are created to evaluate the effects of attributes changing in assembly systems, with influential factors including the change of manufacturing system (push system to pull system) and variation of demand. Moreover, pull system manufacturing consists of the addition attribute, which is the number of buffer storage. This paper will provide an analysis based on a previous case study, hence process time and workflow refer to the journal name “Optimising and simulating the assembly line balancing problem in a motorcycle manufacturing company: a case study” [2]. The implementation of the pull system mechanism is to produce a system improvement in terms of the number of Work-In-Process (WIP), total time of products in the system, and the number of finished product inventory, while retaining the same throughput.

scholarly journals Using lean manufacturing tools to reduce waste and loss in the production process - A case study on a production plant for bottling water -: استخدام أدوات التصنيع الرشيق لتقليل الهدر والضياع في العملية الإنتاجية – دراسة حالة في معمل إنتاجي لتعبئة المياه –

2021 ◽  
Vol 5 (3) ◽  
Author(s):  
Hanan Saleh Jabr
Keyword(s):  
Production Process ◽  
Analytical Method ◽  
Lean Manufacturing ◽  
Raw Materials ◽  
Production Plant ◽  
Market Needs ◽  
Reducing Costs ◽  
Materials Used ◽  
Basic Hypothesis

The research aims to identify the problems that hinder the production process and the most important of these problems is the waste and waste of the available resources, whether in the raw materials used in production or the waste of the time it takes to complete the production process. And the obstacles and benefits achieved from them, using the descriptive analytical method to study the basic hypothesis that says that the use of lean manufacturing tools leads to reducing waste and loss in the production process. The research has concluded that the application of the lean system leads to reducing waste and loss in the production process and thus create value for the customer The use of lean manufacturing tools creates products that meet market needs and according to the level of demand. Among the most important recommendations is the necessity for productive institutions to take into account product quality and not focus on reducing costs in order to meet the customer's desire.

scholarly journals Extending lean manufacturing in supply chains: a successful case in Brazil

2014 ◽  
Vol 21 (6) ◽  
pp. 1070-1083 ◽  
Author(s):  
Ana Beatriz Lopes de Sousa Jabbour ◽  
José Carlos Omodei Junior ◽  
Charbel José Chiappetta Jabbour
Keyword(s):  
Supply Chain ◽  
Six Sigma ◽  
Lean Manufacturing ◽  
Design Methodology ◽  
Lean Six Sigma ◽  
Success Story ◽  
Content Type ◽  
Focal Firm ◽  
Successful Case

Purpose – The purpose of this paper is to present the results of a success story involving the extending of lean manufacturing practices between a focal firm and its supplier, both located in Brazil, thereby configuring a case of excellence. Design/methodology/approach – An in-depth case study was conducted involving two companies: Company A, focal, leader in its segment, located in Brazil; and Company B, Company A's supplier, also located in Brazil. Findings – Results indicate there are several mechanisms for extending lean manufacturing practices in the supply chain, such as workshops, training, and integrated teams. These mechanisms are shown and guidelines are also introduced for companies seeking to successfully extend lean manufacturing practices. Originality/value – An original use of define, measure, analyze, improve, control for structuring the extending of lean manufacturing practices to suppliers and, consequently, the importance of the lean six-sigma relationship in this context. Furthermore, the guidelines introduced serve as a benchmark for other companies interested in the topic.

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