Manufacturing Excellence Model To Solve Operational Risks Due To Product Demand Variations

Abstract

The dynamic product demand impacts the manufacturing supply cycle by creating some operational risks like high inventories, excess manpower, and underutilization of machines, etc. Business firms or companies get impacted financially due to the dynamic product demand with issues like rising finish goods, raw material, and in-process stocks or inventories, inefficient usage of resources like machines, water, and people, and excess or less manpower or job cuts. We studied the lean manufacturing principle in a literature survey to understand the concept of the manufacturing excellence at the product manufacturing and its deployment to solve the above-listed issues due to product demand variations. Further, in research methodology, we considered the independent variable as dynamic product demand and the dependent variable as operational risks like high inventories, excess manpower, and underutilization of machines. We plotted the value stream map for the selected product manufacturing with daily demand 25 and 40 numbers to understand the operation risks that occur after changing the demands. We proposed consolidated manufacturing excellence models for solving the operational risks and after deployment of them; we again plotted the value stream map for the selected product manufacturing with daily demand 25 and 40 numbers. We got gain of in the case of the daily 25 demand, total lead time reduced from 14.6 to 7.82 days that is 46.44% for in-house product manufacturing and in the case of the daily 40 demand, total lead time reduced from 26.18 to 15.18 days that is 42.01%. Total lead time in both cases is reduced by +40% that helped product manufacturing. We conclude this research study as our manufacturing excellence models are successful in delivering the expected results at our selected product manufacturing.