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.

EMBench: An IEC61499 Based Integrated Environment for Manufacturing Systems

2006 ◽  
Author(s):  
Chengyin Yuan ◽  
Placid Ferreira
Keyword(s):  
Manufacturing Systems ◽  
Model Simulation ◽  
Industrial Process ◽  
Value Added ◽  
Global Market ◽  
Shop Floor ◽  
Control Logic ◽  
Software Environment ◽  
Automation Systems ◽  
Control Configuration

In these days, manufacturing organizations are facing global competition and short technological cycles. The flexibility of an enterprise and its ability to respond to miscellaneous customer requests decide the competitiveness in the global market. It also requires that the manufacturing plant must reorganize efficiently to produce various products at low cost and short time. This flexibility in the manufacturing process must be able to accommodate various tasks to share resources under safe and efficient control. In the current development processes of manufacturing systems, information handling usually is an undeveloped area. Domains such as design, validation, and deployment will be separated and isolated. One reason for the redundant non-value-added implementation of the component model is that existing system development largely consists of isolated sub-processes that generate proprietary information such as control logic, simulation models, etc. This paper focuses on introducing an innovative software environment, EMBench, which integrates mechanical design, control configuration, simulation and deployment services seamlessly for manufacturing automation systems. Its auto-generated user-friendly GUI (Graphical User Interface) supports direct commanding to the controller at different layers, and internal data (control/mechanical) and model (simulation/physical) mapping eliminates redundant and error-prone manual data entry and model replication at different stages. This tool provides a means of layered and encapsulated services so that complex systems can be designed, configured, simulated and deployed hierarchically with various levels of details. IEC61499 is an emerging industrial standard for distributed industrial process measurement & control systems. Using IEC61499 function blocks and service layer architecture, control services ranging from basic joint servo, to kinematics of a mechanism, to trajectory interpolation, to language parsing and HMI processing, to complex multiple resources/processes coordination can be configured for an application. With the adaptation of IEC61499, EMBench serves as a modular, component-based design, simulation and prototyping tool for shop floor control. Several case studies are presented in details and various potential usages in different fields are discussed. EMBench uses IEC61499 as a means for modularization and reuse of control services.

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

scholarly journals Improving Distribution Process Using Lean Manufacturing and Simulation: A Case of Mexican Seafood Packer Company

2018 ◽  
Author(s):  
Julián I. Aguilar-Duque ◽  
Juan L. Hernandez-Arellano ◽  
Cesar Omar Balderrama-Armendariz ◽  
Guillermo Amaya-Parra ◽  
Liliana Avelar
Keyword(s):  
Simulation Model ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Model Development ◽  
Production Capacity ◽  
Mathematic Model ◽  
Global Market ◽  
Simulation Software ◽  
Market Demand ◽  
Work In Process

During the last decades, the production systems have developed different strategies to increase their competitiveness in the global market. In a manufacturing and services systems, Lean Manufacturing has been consolidated through the correct implementation of its tools. The present paper presents a case study developed in a Food Packer company where a Simulation Model was considered as an alternative to reduce the waste time generated by the poor distribution of operations and transportation areas for a product within the factory. As a matter of fact, the company has detected problems on the layout distribution that prevents to fulfill the market demand. In addition, the principal aim was to create a simulation model to test different hypothetical scenarios and alternative designs for the layout distribution without modifying its facilities. Moreover, the implemented methodology was based on classical models of simulation projects and a compendium of the manufacturing systems optimization by simulation process used during the last ten years. Also, a mathematic model supported by the Promodel ® simulation software was developed considering the company characteristics; along with the model development, it was possible to compare the production system performance from the percentage of used locations, the percentage of resources utilization, the number of finished products, and the level of Work in Process (WIP). Finally, the verification and validation stages were performed before running the scenarios in the real production area. The results generated by the implementation of the project represent an increase of 68% in the production capacity and a reduction of 5% in the WIP. In addition, both outcomes are associated with the resources management, which were reassigned to other production areas.

scholarly journals Technical, economic, and environmental performance assessment of manufacturing systems: The Multi-layer Enterprise Input-Output formalisation method

2021 ◽  
Author(s):  
Claudio Castiglione ◽  
Erica Pastore ◽  
Arianna Alfieri
Keyword(s):  
Environmental Performance ◽  
Lean Manufacturing ◽  
Manufacturing Systems ◽  
Manufacturing System ◽  
Sustainable Manufacturing ◽  
Flow Analysis ◽  
Material Flow Analysis ◽  
Value Added ◽  
Economic Assessment ◽  
Input Output

In production planning and control, assessing the performance of a manufacturing system is a multi-dimensional problem, in which neglected dimensions may lead to hidden inefficiencies and missed opportunities for gaining a competitive advantage. This paper proposes a data formalisation method to model a manufacturing system by simultaneously considering value creation and technical, economic, and environmental performance. The proposed method combines the techno-economic assessment of lean manufacturing and sustainable manufacturing with the data-driven approach, typical of Industry 4.0, to overcome the limitations of the lean approaches in addressing complex systems. The method is based on integrating Multi-layer Stream Mapping and a combination of Enterprise Input-Output and Material Flow Analysis. It also considers non-value-added activities such as transport and inventories. Pen and papers and digital approaches can simultaneously exploit the method as a shared architecture for formal data integration. The implementation of the method is shown through a numerical example based on a recycled plastic pipeline manufacturing system.

Case Studies on the Implementation of Lean Manufacturing in the Automotive Malaysian Companies

2013 ◽  
Vol 465-466 ◽  
pp. 1180-1184
Author(s):  
Mohd Azhar Sahwan ◽  
Mohd Nizam A. Rahman ◽  
Baba M. Deros
Keyword(s):  
Case Studies ◽  
Cost Reduction ◽  
Lean Manufacturing ◽  
Value Added ◽  
Global Market ◽  
Discrete Manufacturing ◽  
The World ◽  
Mind Set ◽  
Tools And Techniques

Lean manufacturing is one of the initiatives that many major businesses in the world have been trying to adopt in order to remain competitive in an increasingly global market. The focus of the approach is on cost reduction by eliminating non-value added activities. Originating from the Toyota Production System, many of the tools and techniques of lean manufacturing have been widely used in discrete manufacturing. The purpose of this study is to investigate the approach of adopting lean, the tools and techniques implemented, the changes in the organizations, the problems encountered as well as the lessons learnt. This paper describes the results and findings of four industrial case studies conducted in different electrical and electronics companies in Malaysia. Interviews were conducted with the key personnel to answer some issues which were crucial in this study. Comparisons and discussion were made among the case companies. One of the key findings obtained is that people in the organization should take the lean mind-set and act in the lean way in order to make a lean initiative successful. The application of kaizen and 7 quality control tools are most popular implementation in the selected case study companies as the tools to eliminate non-value added activities.

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.

Analysis and Reduction of the Waste in the Work Process Using Time Study Analysis: A Case Study

2014 ◽  
Vol 660 ◽  
pp. 971-975 ◽  
Author(s):  
Mohd Norzaim bin Che Ani ◽  
Siti Aisyah Binti Abdul Hamid
Keyword(s):  
Cycle Time ◽  
Lean Manufacturing ◽  
Value Added ◽  
Time Study ◽  
Study Approach ◽  
Root Cause ◽  
Wide Range ◽  
Unit Of Work ◽  
Time Required ◽  
The Impact

Time study is the process of observation which concerned with the determination of the amount of time required to perform a unit of work involves of internal, external and machine time elements. Originally, time study was first starting to be used in Europe since 1760s in manufacturing fields. It is the flexible technique in lean manufacturing and suitable for a wide range of situations. Time study approach that enable of reducing or minimizing ‘non-value added activities’ in the process cycle time which contribute to bottleneck time. The impact on improving process cycle time for organization that it was increasing the productivity and reduce cost. This project paper focusing on time study at selected processes with bottleneck time and identify the possible root cause which was contribute to high time required to perform a unit of work.

Corporate sustainability assessment through fuzzy TOPSIS

2018 ◽  
Author(s):  
Eleonora Bottani ◽  
Marta Rinaldi ◽  
Federico Solari
Keyword(s):  
Sustainability Assessment ◽  
Corporate Sustainability ◽  
Reference Value ◽  
Fuzzy Topsis ◽  
Analysis And Evaluation ◽  
Sustainability Performance ◽  
Order Preference ◽  
Pros And Cons ◽  
Topsis Approach ◽  
Corporate Level

"The aim of this paper is to propose a decisionmaking methodology that enables the analysis and evaluation of sustainability at the corporate level. The proposed methodology grounds on two tools, namely the technique for order preference by similarity to ideal solution (TOPSIS) approach and fuzzy logic. The integration of these tools offers an effective way to deal with two typical issues of sustainability assessment, i.e.: 1) the fact that the company’s performance should be frequently evaluated against qualitative key performance indicators; and 2) the fact that to be meaningful, the company’s sustainability performance needs to be compared to a reference value, e.g. a threshold or benchmark, to evaluating how the company is distant from a target. The proposed approach has been applied to a real firm, operating in the food machinery industry, for testing purpose. The main pros and cons of the approach are described."

Integration of the concept of lean manufacturing and digital technologies of high-tech enterprises in modern conditions

2020 ◽  
pp. 105-113
Author(s):  
Н.С. Хорошавина ◽  
М.С. Абрашкин
Keyword(s):  
Lean Manufacturing ◽  
Process Management ◽  
Business Processes ◽  
Digital Technologies ◽  
Balance Of Power ◽  
Global Market ◽  
High Tech ◽  
Successful Implementation ◽  
Modern Business ◽  
Business Conditions

Цифровые технологии существенно влияют на мировой рынок, внося коррективы в расстановку сил на нем. Используемые ранее подходы к управлению бизнес-процессами становятся не актуальными в современных условиях. Без цифровизации наукоемкие производства будут не способны выдержать конкурентную борьбу, и вынуждены будут уйти с рынка. В то же время современные условия хозяйствования диктуют необходимость постоянного совершенствования бизнес-процессов наукоемких предприятий, их оптимизации. Данные принципы являются основой концепции бережливое производство, реализация которых становится более эффективной при условии использования цифровых технологий. В статье рассмотрены вопросы интеграции концепции бережливое производство и цифровых технологий на наукоемких предприятиях. Показан пример успешной реализации принципов данной концепции с использованием цифровых подходов к оптимизации бизнес-процессов наукоемкого производства. В современных условиях важнейшим активом любого предприятия, в том числе и наукоемкого производства, являются данные. Реализация принципов бережливого производства требует обработки значительного объема информации. Цифровые технологии позволяют анализировать информационные потоки в режиме реального времени, моделировать бизнес-процессы и тем самым, способствуют более качественному и оперативному принятию решений по оптимизации бизнес-процессов наукоемких производств. Только объединив принципы концепции бережливое производство и возможности, которые дает цифровизация, наукоемкие предприятия смогут не просто удержать свои конкурентные позиции на рынке, но и перейти на более качественный уровень своего развития. Digital technologies significantly affect the global market, making adjustments to the balance of power in it. Previously used approaches to business process management are no longer relevant in modern conditions. Without digitalization, high-tech industries will not be able to withstand competition and will be forced to leave the market. At the same time, modern business conditions dictate the need to constantly improve the business processes of high-tech enterprises and optimize them. These principles are the basis of the concept of lean manufacturing, the implementation of which becomes more effective when using digital technologies. The article deals with the integration of the concept of lean manufacturing and digital technologies in high-tech enterprises. An example of successful implementation of the principles of this concept using digital approaches to optimizing business processes in high-tech production is shown. In modern conditions, the most important asset of any.

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