Abstract
Lean Manufacturing is a popular tool to be implemented in printing industry fields for the purpose of achieving the successful production goals and it is a well-organized method used to eliminate the waste or non-value added activities. Lean Manufacturing consists of several tools like 5S, TPM, Kanban, Kaizen and others. In this paper, the researcher is focus on TPM (Total Productive Maintenance). TPM is a concept used for maintaining plants and equipment with the involvement of all employees in the company in order to increase the overall equipment effectiveness (OEE). In this paper, the researcher will identify the problem faced in company’s production line and then implement lean tools in order to improve the productivity. Afterward, the researcher will carry out time study on company’s production line. The purpose of time study is to getting the result for OEE and the time taken for producing one piece of product. The researcher is then designed and suggested one-piece flow system to the management with showing the result on simulation that getting improvement in productivity. The result was simulated by using Flexsim and shows that 7.59 seconds was saved in producing one piece of calendar. At the end, the result shows that OEE increase from 34.3% to 60% and the company total save around 6 hours per month by implement one-piece flow. At last, by verifying the distribution of collected data, the researcher will perform Anderson Darling Normality test to ensure the distribution of data are normal.
Highlights
The company that involved in this study is ABC Sdn Bhd
Total Productive Maintenance (TPM) focused on solving problem for wastes that related with production system
The overall equipment effectiveness still can be improved by enhancing the TPM and to avoid this current situation return back to original situation
Summary
The company that involved in this study is ABC Sdn Bhd. There are several problems faced by ABC SdnBhd which included low productivity, untidy working environment that affect the effectiveness of process flow, lack of labeling for tools, inventory that cause the space not enough, wastes such as defect, unnecessary motion and lastly is lack of multi-skill workers. The researcher aims to overcome the problem faced by introducing the lean concept. The company’s production flow was identified and 5S was implemented in the production floor for effective flow. The company’s Overall Equipment Effectiveness (OEE) in production layout and redesign layout by using Flexsim software were analyzed. The distance between the stations is far apart from each other which extend the cycle time production as well as the overall transportation distance of work
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