scholarly journals An Application of Lean Manufacturing Techniques in Paint Manufacturing Company: A Case Study

2017 ◽  
Vol 28 (1) ◽  
pp. 51-73 ◽  
Author(s):  
Ahmed M. Badeeb Ahmed M. Badeeb
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Work Place ◽  
Manufacturing Companies ◽  
Pareto Chart ◽  
Value Stream ◽  
Manufacturing Company ◽  
Fishbone Diagram ◽  
Manufacturing Techniques ◽  
Waste Handling

As a result of the recession in Saudi Arabia, the manufacturing companies start thinking to reduce the operational cost and increasing the productivity through lean manufacturing principles. This paper is focused on increasing the productivity of a paint manufacturing company through implementing some of the lean manufacturing techniques. First, Value stream mapping analysis carried on throughout the manufacturing process and the areas of improvements in the company has been identified using fishbone diagram. Second, Work Place Organization (5S), Single Minute Exchange of Dies (SMED), Work Standardization and Kanban are the lean manufacturing techniques selected to solve different problems facing the company in these areas of improvements. A systematic approach of each technique implemented to measure its effect on the company productivity. It is observed that, applying (5S) and (SMED) techniques in the filling process decreased the changeover time by 59% and increased the daily productivity. Pareto chart recommended using work standardization in the charging process led to reduce the defects batches by 57%. Kanban system eliminated the shortages of semi-finish product and increased the output of the pre-weighing batches by 57%. In addition, overtime hours reduced by 77% and waste handling reduced by 85% and 53% for the non-hazardous and hazardous waste respectively

scholarly journals Energy Analysis via Value Stream Mapping: A case study of an Automotive Weld Plant

ORiON ◽  
2021 ◽  
Vol 37 (2) ◽  
Author(s):  
Keshav Ramsunder ◽  
Oludolapo Olanrewaju
Keyword(s):  
Lean Manufacturing ◽  
Sustainable Manufacturing ◽  
Environmental Benefits ◽  
Value Stream Mapping ◽  
Measuring Instruments ◽  
Manufacturing Companies ◽  
Step Method ◽  
Empirical Observation ◽  
Value Stream ◽  
Starting Point

Over the past few decades, Lean Manufacturing (LM) has been the pinnacle of strategies applied for cost and waste reduction. However as the search for competitive advantage and production growth continues, there is a growing consciousness towards environmental preservation. With this consideration in mind this research investigates and applies Value Stream Mapping (VSM) techniques to aid in reducing environmental impacts of manufacturing companies. The research is based on empirical observation within the Chassis weld plant of Company X. The observation focuses on the weld operations and utilizes the cross member line of Auxiliary Cross as a point of study. Using various measuring instruments to capture the emissions emitted by the weld and service equipment, data is collected. The data is thereafter visualised via an Environmental Value Stream Map (EVSM) using a 7-step method. It was found that the total lead-time to build an Auxiliary Cross equates to 16.70 minutes and during this process is emitted. It was additionally found that the UPR x LWR stage of the process indicated both the highest cycle time and carbon emissions emitted and provides a starting point for investigation on emission reduction activity. The EVSM aids in the development of a method that allows quick and comprehensive analysis of energy and material flows. The results of this research are important to practitioners and academics as it provides an extension and further capability of Lean Manufacturing tools. Additionally, the EVSM provides a gateway into realising environmental benefits and sustainable manufacturing through Lean Manufacturing.

Development of Computerize Value Stream System

2014 ◽  
Vol 915-916 ◽  
pp. 1405-1411
Author(s):  
A.N.A. Ahmad ◽  
Sulaiman Hj. Hasan ◽  
H. Norafifah
Keyword(s):  
Lean Manufacturing ◽  
Mapping Method ◽  
Shop Floor ◽  
Value Stream Mapping ◽  
Traditional Concept ◽  
Value Stream ◽  
Stream System ◽  
Manufacturing Company ◽  
Value Streams ◽  
Individual Value

Value stream mapping (VSM) was initially developed to use of the suite of tools to help researcher or practitioner to identify waste in individual value streams and find an appropriate method to its removal. The process itself is simple and straightforward is used to identify waste using lean manufacturing technique, determined causes of the waste through the value stream mapping method and to propose solution to improve workplace environment. In this project is made an attempt to computerize the process though the application of VSM. Computerize value stream system is basically a method which is an internet networking system combining traditional concept of value stream mapping method to be used at manufacturing company to reduce wastes. This paper summarizes the way to develop an internet, online and network based of an efficient computerize value stream system to improve operation value of the manufacturing company. This paper reviews the design of package that will replace the manual method of doing VSM. This package will be applied in a real shop floor environment.

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%.

Lean Manufacturing Implementation in a Gear Shaft Manufacturing Company Using Value Stream Mapping

2015 ◽  
Vol 21 ◽  
pp. 231-237 ◽  
Author(s):  
S. Nallusamy
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Manufacturing Company

Nowadays, Lean manufacturing application is reported for manufacturers in global level.Those reports have exposed that this application has enabled the companies to become competitivethrough the elimination of wastes while producing products and offering services. Various tools like5S, Poka Yoke, Kaizen, Kanban, JIT, etc have been used while implementing lean manufacturingmodel in various types of organization. Recently, both researchers and practitioners have found thatValue Stream Mapping (VSM) technique serves as a powerful vehicle in enabling organizations toimplement lean manufacturing model. Meanwhile, it is found that lean manufacturing model is yet tobe applied in the case of certain manufacturing products. One among those products is gear shaft. Inthis background the theoretical proposition of implementing lean manufacturing model in the case ofmanufacturing a gear shaft has been investigated in this article.

scholarly journals Six Sigma as a method of improving the quality of service process

2018 ◽  
Vol 19 (19) ◽  
pp. 10-15 ◽  
Author(s):  
Kamila Kowalik
Keyword(s):  
Six Sigma ◽  
Service Process ◽  
Value Stream Mapping ◽  
Pareto Chart ◽  
Value Stream ◽  
Sigma Level ◽  
Fishbone Diagram ◽  
Mapping Process ◽  
The Impact

Abstract The objective of the analysis conducted and described in this paper has been to present the practical application of the Six Sigma method based on the DMAIC cycle in improving the quality of the service process. The first part of the article contains the theoretical framework of six sigma and the issue of using its tools in the aspect of services. Afterwards, there has been calculated the initial sigma value which indicated the need for improvement. Measurement phase has been developed by the value stream mapping, process FMEA and customer survey which results have been analyzed in Pareto chart and fishbone diagram. Improve phase includes the Impact&Effort Matrix and target sigma level that can be achieved as a result of failures reducing and service quality improvement.

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.

scholarly journals 2409 An initiative to implement lean manufacturing usng value stream mapping in textile manufacturing company

2014 ◽  
Vol 2014.24 (0) ◽  
pp. _2409-1_-_2409-9_
Author(s):  
Effendi MOHAMAD ◽  
Siti Nur Fatihah AB RASID ◽  
Teruaki ITO ◽  
Mohd Amran Md Ali ◽  
Mohd Amri SULAIMAN ◽  
...  
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Textile Manufacturing ◽  
Value Stream ◽  
Manufacturing Company

scholarly journals Example of Using Lean Manufacturing Tools in Assessing and Improving the Process of Car Arm Rest Production

2018 ◽  
Vol 1 (1) ◽  
pp. 217-222
Author(s):  
Michał Molenda ◽  
Aneta Biernot ◽  
Helena Cierna
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Process Condition ◽  
Value Stream Mapping ◽  
Process Assessment ◽  
Original Condition ◽  
Value Stream ◽  
Organizational Issues ◽  
Manufacturing Company ◽  
Single Production

Abstract The paper deals with the use of Lean Manufacturing tools in improving the production process of car arm rests in a car manufacturing company in Poland. The article describes the original condition of a single production process of assembling ready pieces to produce car arm rests. The original condition was assessed and described with the use of some basic Lean indicators and value stream mapping. The aforementioned tools allowed to assess the process condition and to identify the organizational issues and their sources. It also enabled to reorganize the process and increase its efficiency. The further part of the article describes the results of improvement actions. The process assessment was held and improvements introduced in the first quarter of 2018.

scholarly journals Peningkatan Produktivitas Leaf Spring Jenis Minicup Tipe MMS 2230 dengan Mengurangi Pemborosan Proses Produksi Melalui Penerapan Metode Lean Manufacturing

2021 ◽  
Vol 10 (1) ◽  
pp. 89-100
Author(s):  
Suparno Suparno ◽  
Agus Selamet Susanto
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Leaf Spring ◽  
Effect Analysis ◽  
Productivity Level ◽  
Value Stream ◽  
Mode Effect ◽  
Mapping Analysis ◽  
Fishbone Diagram ◽  
Failure Mode Effect Analysis

PT. Indospring is a manufacturing company that produces various springs for an automotive. Among those various springs, MSM 2230 type is the most produced spring at the company. The big problem in producing the spring was related with the high waste that had impact on the low productivity. The purpose of study was to analyze the waste by using the concept of lean manufacturing particularly to identify and eliminate nonvalue added activities. The study found that there were various wastes which waiting and excessive transportation were two dominant wastes with the contribution to total of wastes at 28.96% and 18.52% respectively. The appropriate tool for further analysis on wastes was selected by using value stream mapping analysis (VALSAT), and process activity mapping (PAM) was the best tool for analyzing wastes more profoundly. The use of PAM and other tools of fishbone diagram and failure mode effect analysis (FMEA) provided important information for improvement. The implementation of improvement displayed potential increase of productivity level by reducing the processing time of the spring from 113,926.83 minutes to 75,960 minutes

scholarly journals Penerapan Lean Manufacturing Untuk Meminimasi Waste Waiting Pada Proses Produksi Hanger Sample Di CV. ABC Offset

2017 ◽  
Vol 4 (01) ◽  
pp. 76
Author(s):  
Ireyna Nissa Octaviany ◽  
Agus Alex Yanuar ◽  
Meldi Rendra
Keyword(s):  
Lean Manufacturing ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Make To Order ◽  
Fishbone Diagram

ABC Offset adalah sebuah perusahaan yang bergerak dibidang percetakan dengan sistem make to order, dimana salah satu produk yang konsisten dipesan adalah hanger sample yang dipesan oleh perusahaan tekstil. Pada bulan Januari, Februari, Juni, Agustus, dan Oktober produksi tidak mencapai jumlah permintaan (73%, 80%, 92%, 71%, dan 50%). Hal tersebut disebabkan oleh permasalahan yang menghambat jalannya proses produksi. Melalui hasil observasi lapangan dan hasil pengolahan kuesioner, diketahui bahwa waste dominan yang terjadi pada proses pembuatan hanger sample adalah waste waiting dan waste inventory, dimana penelitian ini akan berfokus pada waste waiting. Upaya meminimasi waste waiting pada penelitian ini dilakukan dengan menggunakan pendekatan lean manufacturing. Penelitian diawali dengan melakukan pengumpulan data, seperti alur proses produksi, waktu siklus, kuesioner, data permintaan, data produksi, data jumlah operator, dan data jam kerja. Selanjutnya dilakukan pemetaan aliran proses eksisting dengan menggunakan value stream mapping (VSM) dan process activity mapping (PAM) current state. Tahap berikutnya adalah mengidentifikasi akar penyebab waste waiting dengan menggunakan diagram fishbone, diagram pareto, dan 5 whys. Setelah diketahui akar penyebabnya, dibuat usulan perbaikan guna meminimasi waste waiting dimana bidang ilmu yang akan digunakan adalah perancangan tata letak fasilitas dan perancangan produk. Kemudian value stream mapping (VSM) future state dibuat untuk memetakan perbaikan yang akan diusulkan..

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