Implementation of lean thinking through A3 report in plastic injection company (original) (raw)

Reducing waste in production by lean thinking - A Case study

Lean manufacturing or lean thinking is one of the widely used industrial technique worldwide and in India now widely used to improve the production efficiency of the industry by reducing the waste ('muda' in Japanese ) which is the main problem of reducing the production. In presented case study, by using the Poka-yoke, tool of lean manufacturing which means error proofing eliminate the root cause because of which defects or waste are produce in the system. Errors may be in operating or in operation carried out on the particular part. In the presented case study, seventeen percent improvement is done by eliminating root cause of rejection which improves the quality of the product and customer satisfaction.

IJERT-Reducing waste in production by lean thinking - A Case study

International Journal of Engineering Research and Technology (IJERT), 2014

https://www.ijert.org/reducing-waste-in-production-by-lean-thinking-a-case-study https://www.ijert.org/research/reducing-waste-in-production-by-lean-thinking-a-case-study-IJERTV3IS060650.pdf Lean manufacturing or lean thinking is one of the widely used industrial technique worldwide and in India now widely used to improve the production efficiency of the industry by reducing the waste ('muda' in Japanese) which is the main problem of reducing the production. In presented case study, by using the Poka-yoke, tool of lean manufacturing which means error proofing eliminate the root cause because of which defects or waste are produce in the system. Errors may be in operating or in operation carried out on the particular part. In the presented case study, seventeen percent improvement is done by eliminating root cause of rejection which improves the quality of the product and customer satisfaction.

Lean Manufacturing Implementation in a Plastic Molding Industry

Lean manufacturing is a set of tools and methodologies that aims for the continuous elimination of wastes throughout the production cycle. This research addresses the implementation of lean principles and tools in a small and medium scale industry focusing on the Plastic Injection molding operation. The main target is to plan and test several strategies to eliminate waste on the shop floor. A systematic approach was used for the implementation of lean principles. This paper also describes the application of value stream analysis. The present and future states of value stream maps were constructed to improve the relevant production process by looking for opportunities to eliminate wastes and its sources and finally to improve the overall process flow. The implementation of VSM, 5S, SMED, Heijunka, Small lot size, Kanban, milkrun, layout and process improvement have shown very encouraging results. Productivity has increased to 94.1%, Delivery attainment increased to 100%, Changeover time was reduced to 38.5 minutes and reduction in total inventory to 2.86 days. The implementation of lean manufacturing has proven to be effective and suitable for enabling a continuous improvement process.

A Review -“Investigation on Lean Manufacturing”

International Journal of Advance Engineering and Research Development, 2015

Today, numerous companies have a major opportunity to reduce their costs and customer lead time and cycle time through the application of Lean Manufacturing System or Lean Philosophy. Implementation of Lean helps to improve their productivity and efficiency. This paper aim to have a brief study on the literature related to lean philosophy in the manufacturing industries and integrate the different lean tool for getting better productivity in different industries. The outcomes from this review is hope justify the needs of further research in area of Lean Manufacturing, aimed at strengthen its philosophy towards more realistic applications. In addition, the model also shows how lean dimensions in the manufacturing system related to eight types of wastes.

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.,

Literature Review on Implementation of Lean Manufacturing Techniques

International Journal of Advance Research, Ideas and Innovations in Technology, 2015

In competitive environment lean manufacturing is necessary in every industry. Lean production is a standard manufacturing mode of the 21st century. Lean manufacturing have various synonyms like lean management, lean production, It is very use full techniques for reduce the flow of non value added time. Lean manufacturing is a philosophy to reduce the time between customer order and products are ready for the delivery by eliminating waste. Waste (muda) is a serious problem in to the industry it is creates a non value added services and poor quality of the product. Waste are seven type occurs in industry 1) transport,2) inventory,3)motion,4) waiting,5) over production,6) over processing,7) defect. It is eliminate with the help of lean manufacturing. It is an integrated system that gives production of goods/services with minimum buffering costs. This paper gives the literature survey on various type of industry to apply the lean manufacturing, like apply in to automobile industry, and ...

The Perception & Methodology of Lean Manufacturing: A Review paper 1

2015

— In the present global and competitive environment all organizations needs to perform efficiently with higher productivity. For performing efficiently with higher productivity there are so many tools and techniques. Lean is one of them it means using only what is necessary. Lean manufacturing techniques aim to significantly identify waste and eliminate it from the manufacturing processes. The paper is based on a discussion of literature review that shows how the completion of Lean could find importance to the organization processes and contribute for live in competitive environment by fast full benefits i.e. lead time, set-up time, reduction in inventory etc.

LEAN IMPLEMENTATION IN MANUFACTURING INDUSTRY: A CASE STUDY

iaeme

In the present business environment, overproduction refers to excess of production over demand of products being offered to the market. This leads to excessive inventory in terms of finished and semi finished goods. Excess production is only relative to a given demand, and insufficient demand is only relative to a given production and thus consider overproduction and under consumption equivalent. Overproduction is the root cause of imbalances, in production sections thereby; the men & machines are either unutilized or being used for over production. The principles of lean manufacturing are very loud in the subject matter and overproduction is the worst form of waste. In this present case, XYZ Company manufacturing automotive products of the same type but in wide variety was chosen for this comprehensive study. This company has problems in-hand regarding movement of material on shop floor, accumulation of material on shop floor, and waiting time in assembly line etc. The probable solution for above mentioned problems is to apply optimization approaches on production system.

Lean manufacturing – results of selected implementation projects

Journal of Intercultural Management, 2013

Lean Manufacturing is a structured program whose objective is to maximize the effectiveness of the company. It is based on the practices and methods of KAIZEN / LEAN applied by the world’s best companies. The experiences from the Author led us to the conclusion that the Lean Manufacturing is based , among others, on the following concepts: - Total Productive Maintenance TPM - Single Minute Exchange Die SMED The Lean Manufacturing focuses on the systematic pursuit and elimination of waste and losses. The losses identified are analyzed, evaluated in adequate manner to the attribute processes. The result of the analysis determines where and how to intervene. In the paper has been presented the bases of Lean Manufacturing. The results of the implementation of Lean Manufacturing in different companies have been described. The main issues of Lean Manufacturing implementation have been characterized.

A Content Analysis on Lean Manufacturing -Concept and Benefits for Manufacturing Industry

IJRASET, 2021

Nowadays, every organization must be required to determine its strength and weaknesses to enlarge productivity and output of their operations. The concept of lean production system has been acknowledged as a means to increase competitiveness for manufacturing concerns all over the world. The present paper has been planned to analyze the concept of Lean Production and its benefits for manufacturing industries. On the basis of the content analysis, the study found that lean manufacturing is gaining popularity day by day among manufacturing industries due to its potential of increasing operational performance. This is done with the help of its set of tools and principles which are used in the systematic elimination of seven wastes, namely, overproduction; waiting; scrap; conveyance; processing; inventory; and motion. Elimination of wastes enable manufacturer to produce the product with superior quality, lower cost and on time with lesser efforts.