THE IMPACT OF LEAN MANUFACTURING CONCEPTS ON INDUSTRIAL PROCESSES' EFFICIENCY AND WASTE REDUCTION (original) (raw)
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International Journal of Science and Research (IJSR) ISSN: 2319-7064, 2020
Lean production, pioneered by Toyota, is a methodology aimed at minimizing waste in automotive manufacturing processes. Associated with the Toyota Production System (TPS), Lean production involves implementing various tools to optimize production floor design and operation. This paper provides an in-depth exploration of key Lean tools, including Kaizen, PDCA, Standardization, Jidoka, Poka Yoke, Just in Time (JIT), Heijunka, Kanban, 5S, Andon, and SMED. Kaizen, emphasizing continuous improvement, involves all personnel in systematic small-scale changes to enhance efficiency and quality. PDCA, serving as a framework for continuous improvement, involves planning, execution, evaluation, and adjustment. Standardization establishes best practices, ensuring consistency across procedures. Jidoka focuses on quality control, halting processes upon detecting defects. Poka Yoke, or mistake-proofing, prevents errors through mechanical design. JIT aims to produce only what is needed when it is needed, minimizing waste. Heijunka regulates production flow to achieve smooth operation. Kanban facilitates demand-driven production through visual scheduling.5S promotes workplace organization and cleanliness. SMED minimizes setup time for efficient product changeovers. The paper offers detailed insights into each tool's implementation and significance in Lean production, emphasizing their role in waste reduction and process optimization.
Benefits of Implementing Lean Principles to Real Manufacturing Environment
The main purpose of this technical manuscripts to present the benefits of using lean manufacturing tools and principles on dynamic manufacturing environment. Lean manufacturing uses less of everything compared to mass production -half the human effort in the factory, half the manufacturing space, half the investment in tools, and half the engineering hours to develop a new product [1]. It has now become a production method for many manufacturers to pursue. It is a "system for the absolute elimination of waste" [2], where "waste" is defined as everything that increases cost without the creation of value for the final customer . With implementing lean principles through realized project in real manufacturing environment, activities that do not add value to the customer which are presented in seven types of waste eliminated and lean flow which is more effective and economically way of manufacturing goods gained. During this work lean manufacturing to the process of pump production implemented and the following gained: Working stations now provide improved material and information flow, Productivity is increased by 8%, lead time is reduced by 25%, Inventory between working stations is completely eliminated. Kaizen, redesign of layout, setup time reduction and line balancing are the lean tools utilised in this work. Consequently Value Stream Mapping (VSM) is used as a tool to map the present and the future state process.
Lean Manufacturing Practices - a Literature Review
International Journal of Advance Engineering and Research Development
Survival of any industry in this era of globalization & a cut-throat competition becomes extremely difficult. In order to survive, it is necessary to adapt to this ever changing environment. Globalization has made this competition fierce & has also helped in developing techniques & methods that are exceedingly helpful for any industry to flourish even in today's times. Lean is one such tool that can be applied anywhere & everywhere in industry. From shop-floor to the top management, lean has proved its mettle. Application of lean reduces the wastes that are produced & also helps in streamlining the production system. It focuses on continuous improvement & at the same time reducing the wastage. Widely used techniques like Kaizen, 5S, Six Sigma, Value Stream Mapping (VSM) are a part of lean. Implementation of lean leads to all around development of any industry. This paper discusses comprehensive literature on implementation of lean manufacturing. The case studies considered in this paper includes work of international researchers.
Lean Manufacturing Applications in the Manufacturing Industry
MATEC Web of Conferences
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.
JURNAL Al-AZHAR INDONESIA SERI SAINS DAN TEKNOLOGI
This research is based on the fact that many domestic sugar industries operate inefficiently and have low productivity, which is seen when compared to other countries such as Thailand, India and Australia. This study aims to identify and analyze problems along the flow of the white crystal sugar production process that cause waste and then make suggestions for improvements to reduce existing waste to increase cost efficiency in the production process. The national sugar factories generally have a basic problem, namely the low level of factory efficiency, which causes a lot of waste along the flow of the production process. The right concept for solving this problem is the implementation of the Lean manufacturing method, where this method focuses on efforts to reduce waste along the flow of the production process by making continuous improvements. The research begins with a literature study and field study and then conducts observations, analyzes, brainstorms, extracts and collects d...
Lean Manufacturing Methods for Process Improvement
IRJET, 2022
The business environment of today is dynamic, and various businesses are figuring out how to become more skilled and adapt to consumer demands. The necessity for ongoing production process and overall management enhancement is becoming important as a result of the competitiveness's requirement for survival. The study aims to identify wastes in a production process and propose recommendation for improvements. The purpose is also to evaluate the usefulness of various Lean Management tools. A single case study was selected as the research methodology for the study. The approach of value stream mapping has been used to generate the process's present state. Following the mapping, wastes were analyzed and suggestions for improvement were offered.
Understanding the Need of Implementation of Lean Techniques in Manufacturing Industries: A Review
International Journal of Trend in Scientific Research and Development (IJTSRD), 2019
In competitive environment lean manufacturing is necessary in every industry. Lean production is a standard manufacturing mode of the 21st century All the manufacturing industries have put a continuous efforts for its survival in these current world. In order to handle the critical situations manufacturers are trying to implement new and innovative techniques in their manufacturing process. Later on lean was formulated and developed as the solution to the fluctuating and competitive business environment. Due to rapid change in business environment the manufacturing organization are forced to face challenges and complexities in the competition. The concept of lean manufacturing was developed for maximize the resource utilization and minimize the wastes. The main focus of the lean manufacturing is to satisfy customer demands for high quality and low cost. The technique not only identifies the reasons for waste but also helps in its removal through marked principles and guidelines. Lean Manufacturing is an efficient and fast growing approach in the world of competition. Lean manufacturing utilizes a wide range of tools and techniques; the choice of tools is based on the requirement. Many parameters contribute success of lean. Organizations which implemented lean manufacturing have higher level of flexibility and competitiveness. However, lean manufacturing provides an environment that is highly conducive to waste minimization. The majority of the study focuses on single aspect of lean element, only very few focuses on more than one aspect of lean elements, but for the successful implementation of lean the organization had to focuses on all the aspects such as Value Stream Mapping (VSM), Cellular Manufacturing (CM), U-line system, Line Balancing, Inventory control, Single Minute Exchange of Dies (SMED), Pull System, Kanban, Production Leveling etc.,
LEAN MANUFACTURING: PRINCIPLES, TOOLS, TECHNIQUES AND BENEFITS
ijetrm journal, 2021
In manufacturing to profitability improvement applying lean concept can really good. Broad fields of lean manufacturing are simple to get to deal with a broad range of matters found by altered production process. It helps to lessen expenses of the producing products. The elementary Non-Value added Activities were apparent and chances needed for enhancement has been supposed. Value Stream Mapping (VSM) has the position of finding waste during manufacturing and business measure which encourage finding and eradicating or stream the worth added steps. Initiative of lean manufacturing aims on reduction of cost and turnover increases by methodically eradicating non-value-added actions on continuous basis. In current cut-throat setting, lean can be considered as "the solution" to producing firms across the globe for sustained survival.
IMPROVEMENT OF PROCESS CYCLE EFFICIENCY BY IMPLEMENTING A LEAN PRACTICE: A CASE STUDY
„Lean‟ is an established industrial paradigm with proven track record in various sectors of the industry (Womack and Jones, 1996). World-Class multinational companies such as Toyota (second biggest global car manufacturer), Porsche‟s (most profitable Global OEM), Boeing (largest global aerospace business) and Tesco (third largest global retailer) have adopted Lean at the Corporate level. It is an applied methodology and step by step technique that results work tasks in a process to be performed with the least involvement of non-value adding activities greatly resulting in reduced process time, wait time, queue time, operation time, move time, administrative time and other delays. This paper addresses the implementation of Lean Manufacturing in a small scale production industry. The main objective of this practice was to minimize the waste on the shop floor. This paper shows the application of Value Stream Mapping (VSM) in detail. By identifying the waste and its sources the present and future states of value stream maps are developed to improve the production. This improvement technique focuses the benefits of Lean production techniques in various stages of V.M. Auto Parts Pvt. Ltd. and results 6-7% potential cost saving reduction in cycle time and increase in cycle efficiency is guaranteed. The flow process or cycle time was enhanced thus minimizing various non value added actions and times such as bottle necking time, waiting time, material handling time, etc. More generic approach to design lean environment can be developed by this case study. Keywords: Lean Manufacturing, Value Stream Mapping, cycle time, Takt time Cycle efficiency.
Lean Principles Application in the Automotive Industry
Acta Polytechnica Hungarica
In today's competitive environment, the strategic goal of most organizations, is not only to survive, but also to move forward. It is therefore important to examine business processes and minimize waste. Anything that does not add value and contributes to unnecessarily spent funds can be considered to be a waste, so the goal of each community should be to get rid of activities that negatively affect its effective functioning. The aim of the paper is to highlight the possibilities of using Lean principles in the automotive industry. The purpose of using lean manufacturing methods is to eliminate identified shortcomings and wastage, to ensure smoother production and to meet customer requirements, and to reduce business costs and increase its competitiveness on the market. The article describes selected industrial engineering methods that deal with waste elimination (time, transport, waiting, movement, inventory), followed by an example of a specific application of Value Stream Mapping (Yamazummi chart) in automotive companies in Slovakia. This example gives space for discussion on the next direction of Lean principles usage in practice and potential benefits for the future.