Implementation Of Lean Tools Research Articles

Measures for Enhancing Productivity and Efficiency of Small and Medium Scale Industry by Lean Implementation

Objective: To propose appropriate measures for effective implementation of lean tools in small and medium companies. Method/Analysis: At this context, a thorough study made on the performance of four sections namely plating, molding, stamping and assembly. Workers are made aware of the lean tools and implementation. Key Performance Indicators like DL(Direct Labour) Efficiency, TEEP(Total Effective Equipment Productivity) and OEE(Overall Equipment Efficiency) of these sections are measured. Findings: It is found that although some manufacturing sections namely plating, stamping and moulding showed improvements by implementation of lean tools, assembly section had not shown any improvement. Subsequently Hoshin workshops and SMED(Single Minute Exchange of Die) classes are conducted. By these remedial measures appreciable increase in DL Efficiency, TEEP and OEE of assembly section is observed. Application/Improvements:By the above revised lean tool implementation, operational excellence is achieved in all four sections.

A Rational Approach of Lean Tool Implementation to SME - A Case Study

Objective: To analyse the existing method of manufacturing and suggest to implement the appropriate lean tools in small and medium scale industries to improve their efficiency. Method/Analysis: At this context, an assessment is being carried out on productivity and quality factor in various manufacturing sections of a connector manufacturing company with the help of a survey conducted by the research group. Findings: It is observed that manufacturing sections namely plating, stamping and moulding sections showed improvements by implementation of lean tools whereas assembly section does not register any improvement. Application/Improvements: Appropriate remedial measures are taken to get continual improvement. So the necessary suggestions are given to measure the effectiveness of implementation of lean tools.

Lean Implementation and Organizational Transformation: A Literature Review

Manufacturing organizations are constantly striving to develop more effective and flexible means for managing challenges due to globalization and increasing customer expectations. This has led to increased efforts by the business community to research and implement the Toyota Production System, or lean manufacturing, to address these challenges. These efforts have resulted in numerous publications on lean manufacturing, including research reports, scholarly articles, and trade magazine articles. However, the existing body of knowledge on lean manufacturing is disperse and diverse in nature with respect to the application and implementation of lean tools and practices, making it difficult for researchers and practitioners to gain a real grasp of this topic. In this article, we have comprehensively organized the existing work on implementation of lean manufacturing in a more structured way, enabling engineering management practitioners to more easily identify knowledge and best practices and enabling researchers to identify gaps in the extant literature. Lastly, drawing from the organizational science literature, this article also provides important insights on lean manufacturing from the perspective of organizational learning, innovation, and \\culture.

The Hybrid Lean System to Improve Manufacturing Environment

Lean manufacturing is a systematic approch could increase manufacturing competitiveness by identifying and elminating waste through lean tools. However, these tools are often categorized into different groups, continues to be difficult for companies to select the most appropriate lean tool to be adopted, especially in respect of the SMEs whose knowledge of lean tools and associated principles are limited. This study is to propose solution on how to implement appropriate lean tools in food manufacturing industry located at Rengit, Johor. Qualitative method is used as a methodology to see the changes after the implementation of lean tools. Interview session also a part of method to collect data from respondents. The finding from this paper shows that implementation of an appropriate lean tool will help to eliminate waste in industry sector, maintain and control the inventory, improve quality of the product and improve overall operational process.

Lean Tools Implementation for Lead Time Reduction in CNC Shop Floor of an Automotive Component Manufacturing Industry

Objective: To examine the existing system of a production line in a shop floor of steering gear box manufacturing industry and to improve the productivity using lean methodology without much affecting current working systems. Method/ Analysis: An extensive range of lean manufacturing tools are available to take care of all kinds of issues faced by different manufacturing industries. It also helps for successful cost reduction of the manufacturing component and to assure the quality of manufacturer and customer. Findings: The critical Non-Value added Activities (NVA) were recognized and probabilities required for development has been recognized. Value Stream Mapping (VSM) has the reputation of finding waste during manufacturing and business process which facilitate to identify and remove or stream the value added steps and to eliminate the non-value added steps. Application/Improvements: After accomplishment of appropriate lean tools, it was found that the total setup time was condensed by about 180 minutes and cycle time was condensed by about 98 minutes which ultimately reduces the lead time and increases the productivity.

Lean Tools Execution in a Small Scale Manufacturing Industry for Productivity Improvement- A Case Study

Objective: To study and implement the lean tools and to reduce lead time without much affecting the current working systems in a small scale automotive component manufacturing industry. Method/Analysis: An attempt was made in increasing the capacity of a machining cell with appropriate lean techniques. The enhancement of capacity was to be completed with zero capital investment. Findings: A lean approach by using value stream mapping and line balancing was adopted to improve the performance of the manufacturing cell. By collecting the past production data and deciphering the information, gaps were identified for enhancement. Single Minute Exchange of Dies (SMED) was used to regulate the production and Kaizen was also introduced in all work stations. Leveled operator loading for output consistency was suggested. Finally capacity intensification was achieved without any major capital investment. Application/Improvements: Implementation of lean tools reduced the setup time and idle time. The overall lead time got reduced from 6.9 days to 3.6 days and total cycle time got reduced from 170 to 140 minutes and the customer demand was also met on time by the execution of lean tools.

Sustainability of Green Environment though Lean Tool Implementation in Auto Parts Manufacturing Industry – An Industrial Case Study

Lean manufacturing is one of the innovative manufacturing concepts being applied in many industries to avoid the wastages of resources and improving the quality of products. It also provide the application for variety of tools and strategies which can help in identification of waste, reduction or elimination of waste, lowering the product pollution cost, reducing human effort and minimizing product manufacturing time. In general, all manufacturing sectors have lot of impact on environment issues and they have more challenges with business environment. This research focus on the sustainability of green environment through lean tool implementation in an auto parts manufacturing industry in India. Value stream map is one of the Lean tool as playing very productive role in the entire lean process since it is stating current and future conditions when they develop plans to install lean systems. This paper presents a case study carried out in a foundry division of an auto parts industry, where lean tool is implemented for the reduction of waste also describes how environmental performances are improved by eliminating the wastes. The result shows improved performance in the future state map in terms of reduction of non value activities.

Condition monitoring maintenance of aero-engines through LUMS – A method for the implementation of Lean tools

The airliner operators normally rely on condition monitoring techniques to ascertain the airworthiness state of aero-engine and its components. These techniques are proven tools for forecasting any impending failures and also for optimizing the downtime of maintenance. This paper describes the effectiveness of Life Usage Monitoring Systems for assessing the Low Cycle Fatigue Damages. It also explains how well the LUMS helps the operator to estimate the useful operating life available before any potential failure occurs. Thus, LUMS aids the maintenance planning department to convert the unscheduled maintenance into a scheduled maintenance tasks and also enables the operator to contemplate the possibilities of utilizing the Lean Principles in Planning, Scheduling and Controlling of all Maintenance Tasks.

Application of Lean in Aerospace New Product Introduction Project

Application of Lean in AerospaceAftermarket NewProduct Introduction (NPI) project is discussed periodically in the last tenyears. A NPI project is selected from an APU and AMS components repair andoverhaul service center to demonstrate the benefits of Lean application in newcapability project. Several Lean tools implementation in NPI project isanalyzed and conclusion is drawn based on two NPI project metrics and results.

Lean Manufacturing Effects in a Serbian Confectionery Company – Case Study

Abstract Background and Purpose: The objective of this paper was to evaluate effects of implementing lean manufacturing in a Serbian confectionery production company during a period of 24 months, emphasizing observed benefits and constrains. Company ‘case study’ is a leading confectionery producer in Serbia with annual production of more than 25,000 t. Methodology/Approach: The research method was case study. The approach in implementing lean manufacturing was structured in five phases, as follows: (i) training, (ii) analysis of lean wastes on one technological line, (iii) choice of lean tools to be implemented in the factory, (iv) implementation of lean tools in production and maintenance, (v) development of continual improvement sector and further deployment of lean tools. Results: Lean manufacturing tools implemented in the production process were visual control and single minute exchange of dies (SMED). Maintenance process implemented 5S with total productive maintenance (TPM) and problem solving sessions being the tools implemented in both processes. During the observed period, results of these tools showed the following: visual control tables initiated 61 improvement memos out of which 39% were fully implemented; a total of 2284 minor problems had been recorded, with over 95% of issues revealed in due time; total SMED time decreased for 7.6%; 19 problem solving sessions were initiated with 58% of solving effectiveness, and the remaining converted to on-going projects. In maintenance 5S improved from 29.9 to 60.3; overall equipment effectiveness (OEE) indicator increased from 87.9% to 92.3%; mean time between failure (MTBF) increased for 16.4%. Conclusion: As a result of all activities, 20 in-house trainings and 2 ‘kaizen’ events including motivational training have been initiated with 54 documents being revised and improved in order to contribute to more efficient processes.

Critical success factors for Lean tools and ERP systems implementation in manufacturing SMEs

The aim of the work presented in this paper is to determine the most important CSFs which have the strongest impact on the implementation of Lean tools and ERP systems within SMEs. To achieve this aim, a methodology of two phases was adopted: the first phase was a literature review to identify the set of CSFs that have an impact on the Lean tools and ERP systems’ implementation; the second involved the design of a questionnaire and the gathering of data from SMEs regarding the factors which they consider influence the successful implementation of Lean tools and ERP systems. Ten SMEs were involved in completing the questionnaire and the first analysis was based upon the six responses received. This study has indicated that there is a positive correlation between the CSFs for Lean tools and that of ERP systems.

Cycle Time Reduction of a Truck Body Assembly in an Automobile Industry by Lean Principles

Cycle time should be considered a viable option when an organization is trying to improve efficiency, productivity, and cost base and customer responsiveness. Tools of lean manufacturing and line balancing are used to reduce the cycle time in an automobile assembly plant, which contains many non-value added activities and work. Assembly Line Balancing is the process of assigning operations to workstations along an assembly line, in such a way that the assignment is optimal in some sense. This paper deals with studying the existing operation time for assembling, line balancing to avoid station delay, and the implementation of lean tools resulting in a shortening of the cycle time in an assembly line.

Impact of Dynamic Capacity Policies on WIP Level in Mix Leveling Lean Environment

Balancing demand's product variety in production planning is one aspect of variety management challenge. This phenomenon is described in lean systems as mix leveling. This paper approach product mix leveling problem from a dynamic perspective. A system dynamics model is developed to explore the dynamics associated with the WIP level performance at different mix leveling policies in a lean environment. The system captures different lean tools and policies. Results showed that the best WIP performance is sensitive to both the degree of lean tools implementation as well as the capacity scalability level of the system. The presented analysis showed that dynamic capacity is essential for successful mix leveling policies; however, investments in such scalability can be minimized with shorter production cycles as well as efficient JIT implementation. In addition, the positive impact of SMED on WIP accumulation in lean environment was well demonstrated.

A Decision-Making Process for Selecting of Lean Tools Implementation Methods by Means of Analytical Hierarchy Process in Health Center

Decision making is contemplated as a serious task in management context and it becomes more challenging when appropriate alternatives should be selected among various options based on some criteria. Analytical Hierarchy Process (AHP) is one of the multi-criteria decision making methods, which is widely used in management science because of its reliable and acceptable performance. In this study, a novel execution of adjusted AHP in decision making was utilized in a case study in Iran in order to find the best method for application of lean concept among alternatives. Previous-mentioned alternatives are consulting, college student, and internal human resource. Case study results demonstrated that using consultants for carrying out lean tools is the best method. The degree of consistency is satisfactory and proved the accuracy and correction of application of AHP in finding the best method for implementation of lean tools.

Implementation of Lean Tools and Techniques in an Automotive Industry

Implementation of Lean Tools and Techniques in an Automotive Industry

Measuring the impact of Lean tools on the cost–time investment of a product using cost–time profiles

Traditional costing systems consider the accumulation of costs, but not their timing. Value stream mapping presents a good picture of the time consumed and operations performed for the production of a product within a manufacturing facility, but it does not track the accumulation of costs. The cost–time profile (CTP) is a tool that follows the accumulation of cost in the manufacturing of a product through time; and it finds the cost–time investment (CTI), which is an indicator of the use of resources in the manufacturing of a product through quantities and timing. In this paper, the expected impact of Lean implementations on the CTP and CTI is discussed. The CTP is proposed as a useful tool for the evaluation of the improvements achieved by the implementation of Lean tools and techniques.