scholarly journals REDUCING DIRECT LABOR COSTS THROUGH U-SHAPED CELLULAR LAYOUT IN INJECTED AUTOMOTIVE COMPONENTS INDUSTRY

2021 ◽  
Vol 1 (2) ◽  
pp. 52-61
Author(s):  
Teuku Mirwan Saputra ◽  
◽  
Zulfa Fitri Ikatrinasari ◽  
Andira Taslim ◽  
◽  
...  
Keyword(s):  
Job Shop ◽  
Value Stream Mapping ◽  
Labor Costs ◽  
Value Stream ◽  
Automotive Components ◽  
Time Value ◽  
Cellular Layout ◽  
Takt Time ◽  
Lean Tools ◽  
Operation Cost

Reducing direct labor costs can be used to create a low operation cost as the way for winning future markets including injected automotive components. This paper aims to provide an overview of direct labor costs reduction in injected automotive components through a U-shaped cellular layout as part of the lean concept. Over a decade, many types of research had already used the lean concept to solve problems in production activity through lean tools. In this paper, several lean tools such as Takt time, value stream mapping, and U-shaped cellular will be used for reducing direct labor costs that have increased yearly in Indonesia since 2015. Those lean tools will be performed in a job-shop of injected automotive components. After performing the U-shaped cellular layout, the direct labor costs were reduced to 25 % by combining the job held by two operators to become one operator.

scholarly journals Investigation of Wasteful Activities Using Lean Methodology: In Perspective of Kazakhstan’s Construction Industry

Buildings ◽  
2019 ◽  
Vol 9 (5) ◽  
pp. 113
Author(s):  
Md Aslam Hossain ◽  
Assel Bissenova ◽  
Jong Ryeol Kim
Keyword(s):  
Construction Industry ◽  
Value Stream Mapping ◽  
Construction Productivity ◽  
Value Stream ◽  
Survey Results ◽  
Lean Tools ◽  
The Impact ◽  
Lean Methods

Like many other countries, the presence of wasteful activities is very common in Kazakhstan’s construction industry. This severely affects the productivity of construction processes. Lean methodology maximizes the value of a process by minimizing wasteful or non-value adding (NVA) activities. This study aims to explore and quantify the impact NVA items on construction productivity. Several observations were made for construction processes in Astana, Kazakhstan to investigate and quantify various types of wasteful activities. Moreover, a survey was conducted to examine the general understanding of wasteful activities and Lean methods within the construction industry in Kazakhstan. In terms of wasteful activities, a similarity was found between the observed construction processes and survey results. Furthermore, apart from the commonly found seven types of wasteful activities, some other sources of waste, such as “preparation” and “break”, were found from the observations. Finally, wasteful activities were mapped with commonly used Lean tools, as found in the literature, so that productivity can be improved by minimizing NVA activities. From the mapping and the survey results, value stream mapping (VSM) was found to be the most effective Lean tool, since it facilitates increased visualization.

Development of value stream map for an Indian automotive components manufacturing organization

2015 ◽  
Vol 13 (3) ◽  
pp. 380-399 ◽  
Author(s):  
S. Vinodh ◽  
T. Selvaraj ◽  
Suresh Kumar Chintha ◽  
Vimal K E K
Keyword(s):  
Product Line ◽  
Value Stream Mapping ◽  
Implementation Study ◽  
Content Type ◽  
Value Stream ◽  
Automotive Components ◽  
Current State ◽  
Line Construction ◽  
And Performance ◽  
Manufacturing Organization

Purpose – This paper aims to apply Value Stream Mapping (VSM) for enabling leanness in an Indian automotive components manufacturing organization. Design/methodology/approach – The study was initiated with the selection of product line, construction of current state map, identification of various wastes and the development of future state map. The improvement proposals were subjected to implementation and performance measures were quantified. Findings – The expected outcomes of the study include the quantification of wastes, improvement in manpower productivity, quality improvement and throughput time reduction. Research limitations/implications – The implementation study has been conducted in only one manufacturing organization. The experiences gained by the conduct of this implementation study are feasible and deployable in similar manufacturing organizations. Practical implications – The results of the study indicated that significant improvement in lean characteristics is possible as a result of the implementation of VSM. Originality/value – The paper reports a real-time study conducted in an automotive components manufacturing organization. Hence, the contributions are original.

Implementation of Lean Tools in an Automotive Industry for Productivity Enhancement - A Case Study

2017 ◽  
Vol 29 ◽  
pp. 175-185 ◽  
Author(s):  
S. Nallusamy ◽  
M.A. Adil Ahamed
Keyword(s):  
Automotive Industry ◽  
Manufacturing Industry ◽  
Value Added ◽  
Value Stream Mapping ◽  
Lean Principles ◽  
Value Stream ◽  
Whole Process ◽  
Lean Tools ◽  
Cycle Efficiency

Value stream mapping has the reputation of uncovering waste in manufacturing, production and business process. This helps in identifying and removing or streaming value added steps and eliminating non value added steps. In this study the process was analyzed to find an opportunity to drastically reduce the number of actions and to simplify the same. By reducing waste the proportion of value adding time increases in the whole process and the process throughput speed could also be increased. This makes the redesigned process more effective and more efficient. The reengineered process was flow charted in its future state with process steps and information flows re-engineering, simplified and economized. The current layout was analysed to identify and eliminate the non value added activities through lean tools like 5S, VSM and line balancing in a manufacturing industry. From the observed results, it was concluded that the non value added time could be reduced by about 13% while the process cycle efficiency could be increased by about 10%. Virtual simulation was conducted to verify and validate the existing situation as well as to propose the results and the effectiveness of lean principles in a systematic manner with the help of ARENA.

Optimization of Assembly and Disassembly of GP7200 Engine

2012 ◽  
Author(s):  
Chittaranjan Sahay ◽  
Devdas Shetty ◽  
Suhash Ghosh ◽  
Mohammed Islam ◽  
Mark Turner
Keyword(s):  
Aircraft Engine ◽  
Value Stream Mapping ◽  
Total Productive Maintenance ◽  
Standard Work ◽  
Value Stream ◽  
Root Cause ◽  
Takt Time ◽  
Time Cycle ◽  
Set Up ◽  
Quality Tools

Build studies were conducted on three different GP7200 engines at a local aircraft engine manufacturer to reduce cost while improving quality, reducing time (cycle time, takt time and lead time), reducing scrap, rework and reducing injuries (increased safety). The paper describes the development of an efficient and effective Dress and Strip process. This project incorporated standard concepts including, DIVE (Define, Investigate, Verify, Ensure), Takt time, Set-Up Reduction, 6S (Sort, Straighten, Shine, Standardize, Sustain and Safety), Kaizen, Quality control & Quality Information System (QIS) and Quality Clinic Process Charting program (QCPC). Seven Wastes (Overproduction, waiting for the next process, unnecessary transportation of materials, over processing of parts due to poor tool and product design, excess inventories, unnecessary movement, and defective parts from supplier), Standard Work, Total Productive Maintenance (TPM) and Value Stream Mapping (VSM) were used in the project. In addition, tools such as, Relentless Root Cause Analysis (RRCA), Root Cause Corrective Action (RCCA) and Mistake Proofing (MP) have been used in conjunction with other quality tools. Following the successful optimization of the process of assembly and disassembly of these engines, several recommendations were made including redesign of some assembly and disassembly tools. The paper presents an improved Assembly/ Disassembly spaghetti diagram and changes in tool design based on observations.

scholarly journals RANCANG BANGUN MODEL PRODUCTION PRODUCTIVITY IMPROVEMENT DENGAN MENGGUNAKAN LEAN TPM DAN SISTEM DINAMIS

2017 ◽  
Vol 6 (1) ◽  
Author(s):  
Intan Emeralda ◽  
Dorina Hetharia ◽  
Iveline Anne Marie
Keyword(s):  
Fault Tree Analysis ◽  
Actual Condition ◽  
Value Stream Mapping ◽  
Productivity Improvement ◽  
Tree Analysis ◽  
Value Stream ◽  
Root Cause ◽  
Time Value ◽  
Increase Productivity ◽  
Analytical System

<p>Increasing productivity and quality is one of the key to make company stay competitive. Lean<br />TPM approach is one of the way to increase productivity. Problem that usually occur at PT. XYZ is the<br />down time from each line of process production that causing actual production did not reach the target.<br />It is dominantly cause by material shortage, process defect, and machine breakdown. This purpose of<br />study is to develop a production productivity improvement model with Lean TPM approach by using<br />dynamic system. This study is started by measuring the Loss time value, OEE (Overall Equipment<br />Effectiveness) value, and making VSM (Value Stream Mapping) to see the flow of material and waste.<br />This is done to measure the actual condition. With this measurement, we can track which one cause the<br />highest % loss. After that, using the FTA (Fault Tree Analysis) to find the root cause of downtime and<br />waste produced. It needed to construct the existing dynamic model because the problem are complexs<br />and dynamic. In that model, analytical system is done to indentified and imitated the characteristic of<br />those complex systems and also to make the alternative troubleshooting repair solution.</p>

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.

Reduction of Process Lead Time Using Lean Tool - Value Stream Mapping (VSM)

2016 ◽  
Vol 860 ◽  
pp. 74-80 ◽  
Author(s):  
Antor Habib Chowdhury ◽  
Sakib Shahriar ◽  
Tanvir Hossen ◽  
Pallab Mahmud
Keyword(s):  
Lead Time ◽  
Research Work ◽  
Value Added ◽  
Point Of View ◽  
Value Stream Mapping ◽  
Safety Stock ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Lean Tools

The research is designed to reduce production lead time using Value Stream Mapping (VSM). The purpose of this lean tool is to uncover the wastes in supply and production process by separating value-adding and non-value-adding steps first and then reduce non-value added steps. A map shows the current state of the operation is drawn first using the time and flow data. By this non-value added actions are recognized and the waste of time and resources between the steps are also identified. To reduce lead time and streamline the process the map is analyzed. The lead time can be reduced by taking some actions or applying some lean tools. Value adding time in the whole process increases and the process production lead time decreases after reducing the wastes. A future state map is made with new and improved processes. Future state map makes the reformed process more effective and more efficient. It comprises the developments through some value stream symbols used only for this mapping. Bata, a leading shoe company was selected for this research work. To draw the current state map, data was collected from the floor. The wastes identified then which were waiting, motion, inventory & transport. The lean tools that were suggested to apply for reducing these wastes were Kanban, Kaizen, Safety Stock and some manpower adjustment. Kanban is a method to achieve JIT, a system to control the logistical chain from a production point of view and also an inventory control system. Safety stock represents an inventory hedge against problems such as downtime, to protect the system against sudden fluctuations in customer orders or system failures. And Kaizen is the small and continuous improvement methods. The result of the research was quite remarkable as this decreases the lead time by around 8% and increases the capacity by 8.8%. It is feasible to use value stream map in the current situation.

scholarly journals Applying Lean Tools and Principles to Improve Sustainability of Waste Management: A Case Study

2018 ◽  
Author(s):  
Nguyen Dat Minh ◽  
Nguyen Danh Nguyen ◽  
Phan Kien Cuong
Keyword(s):  
Waste Management ◽  
Systematic Approach ◽  
Value Added ◽  
Industrial Wastes ◽  
Value Stream Mapping ◽  
Pull System ◽  
Industry Waste ◽  
Value Stream ◽  
Lean Tools

Lean is one of the systematic approach to achieve higher value for organizations through eliminate non-value-added activities. It is an integrated set of tools, techniques, and principles designed to optimize cost, quality and delivery while improving safety. In Vietnam, industry waste management and treatment has become serious issue. The aim of this research is to present the effective of Lean application for industrial wastes collecting and delivery improvement. Through a case study, this paper showed the way of Lean tools and principles applied for wastes management and treatment such as Value Stream Mapping, Pull system, Visual Control, and Andon.... to get benefit on both economic and environment. In addition, the results introduced a good experience for Vietnamese enterprises in cost saving and sustainable development in waste management.

Time Value Stream Mapping As a Tool to Measure Patient Flow Through Emergency Department Triage

2005 ◽  
Vol 46 (3) ◽  
pp. 108 ◽  
Author(s):  
R.L. Kaale ◽  
D.D. Vega ◽  
K. Messner ◽  
D.R. Eitel ◽  
D.E. Johnson ◽  
...  
Keyword(s):  
Emergency Department ◽  
Patient Flow ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Time Value ◽  
Emergency Department Triage ◽  
Flow Through

Reduction of Cost Employing Lean Supply Chain in Rubber Glove Industry

2013 ◽  
Vol 844 ◽  
pp. 421-424
Author(s):  
Sukonthip Hongpiriyakul ◽  
Nikorn Sirivongpaisal ◽  
Sakesun Suthummanon ◽  
Wanatchapong Kongkaew ◽  
Pallapat Penchamrat
Keyword(s):  
Supply Chain ◽  
Energy Cost ◽  
Cost Reduction ◽  
Lead Time ◽  
Labor Cost ◽  
Value Stream Mapping ◽  
Rubber Glove ◽  
Value Stream ◽  
Time Value ◽  
Lean Supply Chain

Rubber glove industry in the supply chain has become increasingly important because of the significant change in consumer behaviors, which turn to focus on healthcare and disease protection. Thailand is among the leading exporting countries of rubber glove. Under current situation, with high labor cost and energy cost having an impact on production cost, the need for cost reduction in the industry is extremely of concern. This research demonstrates application of the lean supply chain for cost reduction in the industry. The aim is to lower the total supply chain cost by reducing the lead time. Value stream mapping is employed to analyze non valued activities (wastes) in the supply chain. Propositions for eliminating the wastes are presented.

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