Abstract
<p><strong>Purpose:</strong> The purpose of this article is to explore the optimization of internal process is assumed as a critical factor to be capable of answering to the moulds industries. Consequently, it has been considered essential to adopt high-valued methodologies to support tooling industry in order to achieve global competitive advantages. For that purpose, this work aims to apply LEAN principles and techniques to support mould design and manufacturing processes.</p><p><strong>Methodology/Approach:</strong> The methodology used was based on PDCA/DMAIC, with the following stages: Define, Measure, Analyze, Improve and Control. For each stages was taken some of Lean Six Sigma techniques, such as Continuous Improvement, Value Stream Mapping, Pareto analysis and Overall Equipment Effectiveness.</p><p><strong>Findings:</strong> This study results was revealed that there are many areas on the organizations in the Mould Industry, when they utilize otimizations tools obtain hugt successes. With the Pareto analysis was carried out to show that events that contributes the most to the stops. The results were: unavailability of the operator (16.4%), programming the machine (14.4%) and tool exchange (12.4%) In the case of this Mould Industry study was obtained for the CNC machines studies, with the implementation of Lean Six Sigma tools as obtained a improvement about 20% of global OEE.</p><p><strong>Research Limitation/implication:</strong> This research was revealed that there the moulds are Project unique and difficult to analyze. Moreover, this paper reports that the approach LEAN Six Sigma is very interesting for the continuous improvement of processes and profitability of moulds industry.</p><strong>Originality/Value of paper:</strong> This research highlight areas of future research using of quality management methods and Lean Six Sigma tools to analyse and optimize production in the moulds industry. Therefore this research It is considered to promote and adopt high-valued methodologies to support tooling industry in order to achieve global competitive advantages.
Highlights
Most injection mould manufacturers in Portugal are generally characterized by their high technological standards, high engineering knowledge and high performance in terms of overall mould quality and customer service
The injection mould industry has faced several challenges posed by globalization (ISTMA World, 2007)
The challenge listed above result in the need to reduce waste and time without added value, where maximizing the use of high technology resources is relevant and differentiating (WEF, 2016; Henriques and Peças, 2012; Wongwiwat, Bohez and Pisuchpen, 2013). This complexity manufacturing results in a very unstable and dynamic process flows and, as such, waste in the mould production chain is difficult to identify and assess. For overtake this difficulty this paper presents the results of a research aiming to understand the applicability of Lean tools to the mould making industry
Summary
Most injection mould manufacturers in Portugal are generally characterized by their high technological standards, high engineering knowledge and high performance in terms of overall mould quality and customer service. The production process of injection moulds has several difficulties to overtake namely the uniqueness of each mould, the simultaneous production of myriad components from several moulds and recurrent mould design changes asked by the customer (Jorge and Peças, 2018) These companies have a challenge to remain at the level of excellence by responding to an increasingly demanding market in terms of mould complexity, ever shorter delivery times and a continuing and growing environmental concern, together with waste minimization. The challenge listed above result in the need to reduce waste and time without added value, where maximizing the use of high technology resources is relevant and differentiating (WEF, 2016; Henriques and Peças, 2012; Wongwiwat, Bohez and Pisuchpen, 2013) This complexity manufacturing results in a very unstable and dynamic process flows and, as such, waste in the mould production chain is difficult to identify and assess. The underlying principle at continuous improvement is it guided towards the efficiency of the global process (Jorge and Peças, 2018)
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