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 Productivity improvement in the production line with lean manufacturing approach: case study PT. XYZ

2018 ◽  
Vol 154 ◽  
pp. 01093
Author(s):  
Halimatussa’ diah ◽  
Ali Parkhan ◽  
Muchamad Sugarindra
Keyword(s):  
Production Line ◽  
Lean Manufacturing ◽  
Textile Industry ◽  
Value Added ◽  
Value Stream Mapping ◽  
Competitive Strategies ◽  
Productivity Improvement ◽  
Value Stream ◽  
Current Production

The increaseing productivity is one of the competitive strategies that can be applied in a company in order to survive in an intense competitive presure. PT. XYZ is a textile industry manufacturing golf gloves and caddy bag. Every day, the company has a production target of 600 pieces per line. However, the desired target is not achieved that it will affect the delay in delivery of products to customers. In this research, a case study on implementing value stream mapping and Kaizen as the lean manufacturing concept is reported. The purpose of this study is to map the current production line, analyse and design the future value stream mapping by eliminating waste occured. It is obtained a lead time reduction as much as 440.4 seconds through eliminating 17 non-value added activities. Then, the output can be increased up to 21% which is equal to 502 pieces.

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.

Optimization of Process Flow in an Assembly Line of Manufacturing Unit through Lean Tools Execution

2018 ◽  
Vol 38 ◽  
pp. 133-143 ◽  
Author(s):  
S. Nallusamy ◽  
V. Saravanan
Keyword(s):  
Lead Time ◽  
Manufacturing Industry ◽  
Assembly Line ◽  
Value Added ◽  
Value Stream Mapping ◽  
Lead Times ◽  
Productivity Improvement ◽  
Value Stream ◽  
Lean Tools ◽  
Lean Methods

The main aim of this study is to achieve the maximum productivity in an assembly line of a valve manufacturing industry through the implementation of different lean tools to minimize the production time. The existing manufacturing data were collected and interpret the information’s for identifying the gaps for productivity improvement. For obtaining the production line performance we shall introduce a solution after finding the problemswhich affects the lead time. In this research, an attempt was made to introduce a new fixture with appropriate lean methods by focusing on value stream mapping, kaizen etc to eliminate different kinds of lead times consuming phases in the overall process. Designing a fixture for the process is also done in Kaizen, in order to exclude the sub operations. After execution of various lean tools the total cycle time was reduced about 10.49 minutes and the productivity was improved about 20% by eliminating all those non value added activities in the operations to meet the customer demand.

scholarly journals VALUE STREAM MAPPING (VSM) BASIC TRAINING TO INCREASE INDUSTRIAL PRODUCTIVITY

ICCD ◽  
2019 ◽  
Vol 2 (1) ◽  
pp. 123-126
Author(s):  
Zulfa Fitri Ikatrinasari ◽  
Kosasih Kosasih ◽  
Nico Alexander Vizano
Keyword(s):  
Information Flow ◽  
Material Flow ◽  
Lean Manufacturing ◽  
Value Added ◽  
Value Stream Mapping ◽  
Basic Training ◽  
Value Stream ◽  
Industrial Productivity ◽  
A Company

Value stream mapping (VSM) is one of the tools in Iean manufacturing that can be used to improve the efficiency of a company. VSM can describe material flow and information flow from upstream to downstream, from suppliers to consumers. VSM can be used to identify waste through sorting each activity into value-added or non-value-added activities. VSM training that begins with providing understanding of the concept of lean manufacturing is expected to increase the ability of workers to improve and enhance the performance of their companies. This training gives good results, seen from the results of discussions and presentations of each group in a given case study

scholarly journals Case Study: Maintenance Proposal of Press Parts Production for Minimize Waste by Lean Manufacturing – Value Stream Mapping (VSM)

INSIST ◽  
2017 ◽  
Vol 2 (1) ◽  
pp. 6
Author(s):  
Dessy Agustina Sari ◽  
Sukanta Sukanta
Keyword(s):  
Lean Manufacturing ◽  
Lead Time ◽  
Value Added ◽  
Value Stream Mapping ◽  
Problem Solution ◽  
Value Stream ◽  
A Value ◽  
Material Transportation ◽  
Schedule Activity

Abstract—Higher competition in businesslike field demanded each company acted as a value creator with progressive fixing performance. One of effort in increasing productivity was reducing waste. Enterprise T have seven type of extravagance were over production, transportation, inventory, over processing, motion waiting and defect. Minimize waste have bond with production time which could increase efficiency on using electricity and decreased lead time. Production process in this company showed non-value added time such as excessively material transportation in picking area and so the workers too much waited for the next schedule activity. This condition caused higher product lead time. Lean manufacturing idea necessary was implemented with using tool Value Stream Mapping – VSM. This strategy would resumed for the company maintenance and the result showed that lacking as much 26,45% of lead time could be a problem solution. Reducing lead time could be higher if the company have applied and played continue improvement.Keywords—lead time, lean manufacturing, value stream mapping.

An Application of Value Stream Mapping in Ceramic Tile Industry: A Case Study

2015 ◽  
Vol 789-790 ◽  
pp. 1283-1286
Author(s):  
Orapadee Joochim ◽  
Siripong Jungthawan
Keyword(s):  
Ceramic Tile ◽  
Manufacturing Process ◽  
Lean Manufacturing ◽  
Current System ◽  
Value Added ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Product Delivery ◽  
Color Mixing

The purpose of this paper is to increase the productivity of a ceramic tile manufacturing process using lean manufacturing technique. The current system of the ceramic tile manufacturing process has been mapped using Value Stream Mapping (VSM) tool, which is a lean manufacturing tool and the wastages in the current system are identified. Afterwards, future state has been created by using VSM tool, which has enhanced process ration by decreasing maximum possible waste in the manufacturing process. The case study demonstrates how the VSM tool has been used to identify and reduce waste in the manufacturing process by 26%, unnecessary inventory by 8.33% and working time of the color-mixing department by 21.57%. This flexibility enhancement causes 2.67% shorter lead time, 2.70% higher value-added ratio and frequent product delivery leading to more profits.

The Effectiveness of Value Stream Mapping (VSM) as an Improvement Tool for the Manufacturing Operation

2014 ◽  
Vol 575 ◽  
pp. 905-909 ◽  
Author(s):  
Mohd Norzaimi Che Ani ◽  
Mohd Adib Razali ◽  
Kauthar A. Rhaffor
Keyword(s):  
Lean Manufacturing ◽  
Raw Materials ◽  
Value Added ◽  
Handling Time ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Data Problem ◽  
Process Operation ◽  
Manufacturing Techniques

This paper presents the application of the Value Stream Mapping (VSM) as improvements tools at selected case study industry. A VSM process is the transformation of raw materials into finished goods and considered interaction of information, operators, machines and materials. The objectives of this project are to study critical wastes in production line and to recommended new design layout based on Lean Manufacturing techniques. Lean is about performance more with minimized the time, inventory, space, labor, and money. The tool of VSM used in this project successfully achieved its objectives to identify waste and proposing the solution for regarding problems. The lead time was reduced by half, the value added ratio was increased drastically and the cycle time was improved by minimize the handling time. VSM was a magical tool that cans reveals of all the data, problem, process, operation and overall flow of processes to make a certain product.

Productivity Improvement in Plastic Bag Manufacturing through Lean Manufacturing Concepts: A Case Study

2011 ◽  
Vol 110-116 ◽  
pp. 1975-1982 ◽  
Author(s):  
Tahera Yesmin ◽  
Md. Masuduzzaman ◽  
Ahmed Zaheer
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Bottom Line ◽  
Productivity Improvement ◽  
Strategic Issues ◽  
Value Stream ◽  
Strategic Role ◽  
Plastic Bag ◽  
Tools And Techniques

In the fiercely competitive market, productivity improvement always plays a key strategic role in determining bottom-line success for an industry. Being a plastic bag manufacturer, which is widely used as packaging material for apparel industry, the manufacturer belongs to a group of backward linkage industry, which is highly competitive. As such, the company has to focus heavily on three strategic issues: reduction in overall cost, improvement in quality with right assurance scheme, and improvement in productivity with right tools and techniques. This research has been conducted in a large FDI-based plastic bag manufacturing company, a techno-economic consortium of Dutch, China and Bangladesh, and located in the suburban area of Dhaka, the capital of Bangladesh. This research was aimed to focus on these issues along with future guidelines as to how to approach lean manufacturing as a pursuit to achieve the ultimate goal of “near perfection”. All of these improvement efforts are planned around the concepts of lean manufacturing. This involves application of Value-Stream Mapping (VSM) and 5S program.

scholarly journals Application of lean manufacturing method and BLOCPLAN algorithm for productivity improvement of a laundry soap bar production

2018 ◽  
Vol 197 ◽  
pp. 14004 ◽  
Author(s):  
Ukurta Tarigan ◽  
Uni Pratama P Tarigan ◽  
Akbar Rizky Rifangi
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Value Added ◽  
Value Stream Mapping ◽  
Minimal Distance ◽  
Laundry Soap ◽  
Productivity Improvement ◽  
Manufacturing Method ◽  
Value Stream ◽  
Cycle Efficiency

The problem experienced by the manufacturing company that produces soap bars is the waste in its production process. The research objective is to reduce waste in the production process flow in terms of distance of displacement of the material nor heap of material of the production process of laundry soap bars so it can increase the productivity. To solve the problem, implementation integration of lean manufacturing and BLOCPLAN algorithm is used. In the early stages, value-added activities and activities that are not value-added is identified through the depiction of value stream mapping, and value-added activities that are not reducible to the application of the principle of 5W and 1H. To get the total minimal distance to move materials, it is necessary to re-layout production facilities with BLOCPAN algorithm. Future state mapping is used to get an idea of the final result, in which all non-value added activities can be reduced, and the shorter lead time obtained in the production process. With the application of those two methods, process cycle efficiency is increased 33.62% resulting in increased productivity of the company amounted to 204 packs of soap bars each day.

scholarly journals Case Study: Maintenance Proposal of Press Parts Production for Minimize Waste by Lean Manufacturing – Value Stream Mapping (VSM)

INSIST ◽  
2017 ◽  
Vol 1 (1) ◽  
Author(s):  
Dessy Agustina Sari ◽  
Sukanta Sukanta
Keyword(s):  
Lean Manufacturing ◽  
Lead Time ◽  
Value Added ◽  
Value Stream Mapping ◽  
Problem Solution ◽  
Value Stream ◽  
A Value ◽  
Material Transportation ◽  
Schedule Activity

Abstract—Higher competition in businesslike field demanded each company acted as a value creator with progressive fixing performance. One of effort in increasing productivity was reducing waste. Enterprise T have seven type of extravagance were over production, transportation, inventory, over processing, motion waiting and defect. Minimize waste have bond with production time which could increase efficiency on using electricity and decreased lead time. Production process in this company showed non-value added time such as excessively material transportation in picking area and so the workers too much waited for the next schedule activity. This condition caused higher product lead time. Lean manufacturing idea necessary was implemented with using tool Value Stream Mapping – VSM. This strategy would resumed for the company maintenance and the result showed that lacking as much 26,45% of lead time could be a problem solution. Reducing lead time could be higher if the company have applied and played continue improvement.Keywords—lead time, lean manufacturing, value stream mapping.

Sign in / Sign up

Export Citation Format

Share Document