Abstract
This paper reports a case study using a standardization process for increasing efficiency and a better optimization of resources in a printing company with 150 operators having manual and mechanical tasks in the box assembly department along with four production lines. The current capacity is 350 boxes per day, while the demand is 650 units, where the company is expected to pay large sums for overtime. Using work standardization, studying worker movements, timing, and workstations redesign, the main goal was to increase the efficiency and productivity indexes. After applying those tools, the inefficient movements in operators decreased from 230 to 78, eliminating 66% of the unnecessary movements, as well as the standard time in a workstation decreased from 244 to 199 s (18.44%) per each assembled box, and the production rate increased by 63.2%, that is, 229 units per assembly line a day, where overtime was reduced to zero.
Highlights
IntroductionRegarding bottlenecks and unbalanced production lines, several studies have presented different types of case studies on manufacturing companies
In practical terms, in order to remain competitive, manufacturing companies must be able to effectively solve a range of production-related issues, such as bottlenecks and unbalanced production lines, shutdowns, late deliveries, extra work hours, inefficient material handling and movements, as well as high production costs, among others.Regarding bottlenecks and unbalanced production lines, several studies have presented different types of case studies on manufacturing companies
In order to demonstrate the importance of Standardized work (SW), a case study conducted in a publishing company is presented, which employs 150 workers and has an operational infrastructure that comprises both mechanical tasks and manual tasks
Summary
Regarding bottlenecks and unbalanced production lines, several studies have presented different types of case studies on manufacturing companies. Processes 2019, 7, 646 studies where maintenance problems were caused by bottlenecks in complex manufacturing systems. In these cases, the result was the production loss. Ren et al [2] displayed a case study where bottlenecks and unbalanced production lines caused low productivity in an assembly area. In order to solve this problem, these authors performed a re-layout of the assembly and balanced in the production lines, productivity increased. Zupan and Herakovic [3] presented a case study of two production lines where bottlenecks caused them to become unbalanced, the company had low productivity. To increase productivity, these authors implemented the balancing line approach
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