Abstract

AbstractThis study aimed to identify the causes of significant problems existing in the metallurgical sector, and a solution is proposed for the setup process. We detail the theoretical background of the processes in the lean manufacturing methodology, which will be applied to a rolling machine. Further, we provide a brief description of the company and the sector’s problems. We describe success stories of companies that implemented various lean manufacturing tools. We also present some of the results achieved across sectors to gain an in-depth understanding of the technique and a practical support of the implemented model. Our proposal is based on the lean manufacturing methodology; tools such as Single Minute Exchanges of Dies, Kaizen, 5S, and value stream mapping (VSM) will be used to reduce setup times and to impact machine layout and productivity positively. We also show the implementation results of a pilot plan conducted in the company over a period of more than 3 months.KeywordsLean manufacturingSetup5SSMEDAvailabilityMetallurgy

Highlights

  • This study presents the case study of a company dedicated to the transformation of nonferrous metals

  • Setup times were reduced from 48.96 min to 28.44 min, that is, a 42% reduction

  • The SMED implementation was focused on solving all the problems related to work standardization in the setup process, motion improvement, and setup time reduction

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Summary

Introduction

This study presents the case study of a company dedicated to the transformation of nonferrous metals. This company faces problems related to low productivity, an environment with poor order and cleanliness, and the lack of standardization in the setup process. These factors directly affect the process flow effectiveness, causing unnecessary motion, excessive worker downtime, and high setup times. We identified the process flow of the representative “busbar” product by means of a current state value stream mapping (VSM). We mapped the process flow and started the implementation of specific tools such as SMED to standardize activities and reduce

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