Lean Manufacturing Implementation in a Plastic Molding Industry (original) (raw)
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Lean Manufacturing: Waste Reduction Using Value Stream Mapping
E3S web of conferences, 2018
Cristal Sri Sujarwati is a small medium enterprise (SME) that produce keripik salak in Sleman, Yogyakarta. To survive and win industrial competition, Cristal Sri Sujarwati was required to improve its performance. But in reality there was a lot of waste in order fulfillment processes marked by ineffective and inefficient work. In this research, lean manufacturing aims to identify and eliminate waste so that the company could improve its performance in winning the industry competition. Lean manufacturing is a systematic approach used to identify and eliminate waste. This lean concept could improve responsiveness through waste reduction, continuous improvement and cost reduction. In order to identify and eliminating waste, a value stream mapping tools, waste weighting questionnaire, value stream analysis tools, and fishbone diagram are used. From the results of research, the dominant waste in the production process was waste defects, waiting, and unnecessary inventory. To eliminate waste, process activity mapping (PAM), the one of detailed mapping tools in VALSAT are used. From the results of the improvement recommendations analysis, lead time decreased by 80 minutes. From the analysis using PAM, there was a reduction of NVA activity from 3.10% to 1.01%.
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...
Materials Today: Proceedings, 2018
The paper principally aims to implement the emerging trend of making an organization 'lean', in a small scale industry. A Lean manufacturing framework is developed using value stream mapping for a plastic bags manufacturing unit. It consists of mapping the current process of the industry and evaluating the same to identify wastes and bottleneck processes. Based on the 7 wastes of lean manufacturing, solutions are suggested to remove the wastes identified. A future state map based on suggested solutions is created. Both current and future state map are simulated and analysed for different attributes such as TAKT times, production lead times, processing time to evaluate the overall gain achieved by using value stream mapping. Simulation results predicted a reduction in TAKT time from 46 minutes to 26.6 minutes. Number of rolls made per day increased from 28 to 50. Implementation of lean manufacturing framework increased the value added time by 74.5%. Simulation results indicate that framework maybe applicable to various other small scale industries.
2013
Lean manufacturing is a production system, which was first developed by Toyota Production Systems (TPSs) to reduce wastes while improving the operational and environmental performance of manufacturing and industrial businesses. While the global industrial market suffers from gnarled competition, lean manufacturing philosophy is providing an effective methodology to reduce cost and maximize profit. In addition, the market no longer accepts waste caused by out of control production or inefficient processes. A commitment to quality and lean operations will result in quality improvement, waste elimination and reduction in time and costs. Value stream mappings (VSMs), a lean manufacturing tool, which originated from the Toyota Production Systems (TPSs), is known as “material and information flow mapping.” This mapping tool uses the techniques of lean manufacturing to analyze and evaluate certain work processes in a manufacturing operation. This tool is used primarily to identify, demonst...
Lean manufacturing is an operational strategy oriented towards achieving the shortest possible throughput time by eliminating wastes (Muda). The research investigation addresses the application of lean manufacturing in an auto part manufacturer which manufactures critical components of an IC engine. The main objective of this research investigation was to identify key areas of non-value added activities by utilising ‘value stream mapping’ (VSM) and then to propose required changes to reduce throughput time based on the principles of lean manufacturing. Three different improvements were suggested as solutions for non-value added activities that were identified in the current state map, which accounted for 250 hrs of throughput time. A reduction of 140 hrs in the throughput time was estimated by incorporating the improvements.
Lean Manufacturing: An Approach for Waste Elimination
International Journal of Engineering Research and, 2015
Lean Manufacturing (LM), a manufacturing system and philosophy, was originally developed by Toyota, Japan and is now widely practiced by many manufacturers throughout the world. Lean manufacturing is a systematic approach to identifying and reducing waste (non value-added activities) through continuous improvement by flowing the product at the pull of the customer in pursuit of perfection. LM is important, primarily because of waste reduction and reduction in lead time. The objective of this paper is to identify Lean manufacturing practices in small scale industries. For this purpose some case studies were chosen and critical observations are identified. Some of these annotations are improper utilization of resources, quality tools for improvements and improper plan for location and layout. This paper includes one case study with the initiatives, observations, results and conclusions of the study carried out in a small scale industry.
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 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.
Lean Manufacturing Implementation Through Value Stream Mapping: A Case Study
Jurnal Teknologi, 2014
Lean Manufacturing (LM) is a business strategy that was developed in Japan. The main contribution of lean manufacturing is the identification and elimination of waste. Companies apply LM to sustain their competitiveness over their competitors by improving the manufacturing system’s productivity and quality enhancement of the product. The goal of this paper is to apply one of the most significant lean manufacturing techniques called Value Stream Mapping (VSM) to improve the production line of a company that produces several components for vehicle assembly line by decreasing the waste and non-value added activities. First, the current value stream map of production line was developed using personal interviews, observations and secondary data of the company. Subsequently, the future value stream map was proposed based on the lean manufacturing principles to improve total production lead time and value added time. Based on the final result it can be concluded that VSM is a useful and a...