Takt Time Research Articles

Integration of lean manufacturing system with novel intuitive fuzzy syncretic lean frame work to improve the overall equipment effectiveness

Lean manufacturing embraces the principle of doing more with less by removing non-value-added activities from manufacturing processes to preserve effectiveness, flexibility, and profitability. Predictive maintenance in production stages are more critical since it involves machines which are prone to failure and a post failure maintenance stagnates the production which creates bottlenecks due to machine failures. Hence in this work a novel intuitive fuzzy syncretic lean frame work has been implemented to incorporate the need of intelligent systems. The framework is divided into phases which employs Fuzzy logic with embedded smart sensors for effective utilization of man machine and materials in order to improve the effectiveness of a production floor. A novel time based forecasting is done in the design phase which implements the lean tool Takt time. The manufacturing phase uses the sensors to determine the predictive maintenance of the machines thereby implementing continuous flow as the lean tool and the inspection phase uses smart sensor system for real time continuous monitoring of the machining process thereby incorporating Poka-yoke as a lean tool. Thus by implementing the framework the overall equipment effectiveness is achieved which helps in achieving continuous flow of products and defect free products in any production firm.

B-107 Advancing Parasitology Laboratory Quality and Processes Through Artificial Intelligence (AI) and Automation

Abstract Background This research emphasizes the profound impact of intestinal parasitic infections on developing countries, particularly in regions such as sub-Saharan Africa, South and Central America, China, and East Asia. With over 1.5 billion people globally affected and 450 million facing serious illness and a mortality rate of 155,000 cases per year, the socio-economic hindrances posed by these infections necessitate innovative approaches for control and eradication. The integration of artificial intelligence (AI) and machine learning (ML) into parasitology, exemplified by the “Automated Diagnosis of Intestinal Parasites” (ADIP), from brazilian Portuguese “Diagnóstico Automatizado de Parasitas Intestinais” (DAPI) system, showcases a paradigm shift. This advanced system, combining simple and complex decision-making mechanisms, demonstrates promising results, achieving high agreement compared to TF-Test (three fecal test). Methods Data were extracted through reports from the laboratory information system (LIS) from January-December 2023. TF-test was replaced by ADIP system in October 2023. Data were analyzed using Microsoft Excel software, with a bibliographic survey in national and international repositories. Results The parasitology laboratory of AFIP implemented artificial intelligence (AI) with ADIP equipment associated with system LIS automation, automating the analysis of approximately 38,000 monthly stool samples. The ADIP classification, image analysis and subsequent algorithm allowed a reduced examination time, since approximately 90% of samples could be released automatically, optimizing the whole process. In addition, after a three-month period using only ADIP, positivity results increased from 7,63% (TF-test) to 9,53%. Our database is periodically reviewed by specialized professionals who validate positive results, ensuring the security of information obtained by artificial intelligence, bringing efficiency, safety, and quality to the laboratory processes. Conclusions Artificial intelligence (AI) in parasite identification and the automated results system promises a bright future. Collaboration between the scientific community and data scientists is crucial to enhance laboratory processes. Through these tools, it is possible to focus on continuous improvements, increased efficiency, and, most importantly, without sacrificing accuracy and result quality. With new technologies associated with the parasitology field, detailed records can be ensured, previously challenging to obtain, showcasing each step from result acquisition to issued report. Process improvement in parasitology brings optimizations, suggesting the potential for team reduction without compromising quality and improving the takt time.

An investigation of mixed-model assembly line balancing problem with uncertain assembly time in remanufacturing

In recent decades, remanufacturing has emerged as an effective way to address resource crises and environmental pollution issues. Unlike traditional manufacturing, remanufacturing production is filled with various variable factors, especially in the assembly phase. Due to changes in part types, quality conditions, and assembly methods, the assembly time becomes highly uncertain. Assembly line balancing is a key challenge to achieve the stable operation of remanufacturing system. This study proposes an evaluation method for remanufacturing assembly time and establishes a multi-objective mathematical model for balancing remanufacturing mixed-model assembly (RMMA) line. The evaluation method utilizes the Fuzzy Graphical Evaluation Review Technique (FGERT) network to predict expected assembly time for each operation. The balancing model aims to optimize remanufacturing takt time and comprehensive balance rate (CBR). To effectively solve this model, an adaptive double-layer genetic algorithm (ADGA) is designed, where layer I ensures production efficiency and layer II optimizes assembly line balance. Finally, an assemble example of high-pressure common rail fuel pumps (HCRFP) is used to validate the effectiveness of the proposed method. The results demonstrate notable improvements compared to traditional single-product assembly (TSPA) line in scenarios with workstation numbers 4, 5, 6, and 7. Specifically, the production takt time is reduced by 4.19% to 9.56%, and CBR is enhanced by approximately 50%. Further comparison with three other classic algorithms confirms the superiority of ADGA. Additionally, it is observed that remanufacturability (proportion of remanufactured parts) has a significant impact on assembly performance. As remanufacturability increases, both takt time and CBR increase, reaching their maximum values when remanufacturability is around 0.5.

Lean methodology in health care practice: an example of application for clinical laboratory urinalysis processing.

Improving quality and laboratory testing turnaround time (TAT) is a constant challenge for a clinical laboratory. The formulas that describe the best way to manage these goals are outlined in International Organization for Standardization standards. According to standards, improvement must be timely and continuous. Lean methodology is a tool to meet this requirement. One of the fundamental elements of Lean is a systematic approach to process improvement by removing waste to create value for the end-user (eg, patient) of the service. This methodology can be adapted in resource-limited settings. The aim of this study was to test the application of Lean methodology in urinalysis. Lean has various collections of tools and concepts. We applied the most useful for the clinical laboratory: Gemba walk, Takt time, cycle time, and value-stream mapping. Finally, we created and approved workplace standards to improve the performance of urinalysis. We compared the TATs of urinalysis tests before optimization, immediately after, and long after (~5 months). We found that TATs had significantly shortened. The TATs of emergency (STAT) urine tests immediately after optimization improved: automated microscopy to 16% (P =.194), fully automated test-strip to 23% (P = .0172), and standardized urine sediment examination to 20% (P =.0048). The TATs of routine urine tests also improved immediately after optimization: automated microscopy to 18% (P <.0001), fully automated test-strip to 11% (P =.0025), and standardized urine sediment examination to 18% (P =.0011). After 5 months of Lean application within the urinalysis laboratory, TATs of routine urine tests remained improved; however, the improvement of STAT urine test TATs dropped to approximately 4%. The application of the Lean methodology shows significant improvement in TATs of processes in our laboratory.

Enhance Productivity In The Garment Industry Through A Modified Value Stream Mapping Approach

The objective of this study is to overcome problems that occur in the garment industry, the company has tried to develop an agile system to increase productivity in this industry. The garment company that focusses on the production of woven bottoms and outerwear, noted that women's woven bottoms products have the highest demand throughout 2022. However, the company was unable to meet Brand demand of 3.5%. Production data shows defects in products, low quality raw materials, and unstable production processes. A modified Value Stream Mapping (VSM) methodology is use to consider all aspects of production. The results of traditional VSM and Value Stream Analysis Tools (VALSAT) analysis include current state and future state, identification of value added and non-value-added elements during the production process, as well as setting priorities to reduce waste in the production process, especially in inventory (19%), defective parts (17%), and transportation (15%). Based on the VALSAT matrix, Process Activity Mapping (33.5%), Supply Chain Response Matrix (21.6%), and Demand Amplification Mapping (15.3%) were obtained. The findings of this research are Pilot Run, which succeeded in becoming an agile and reliable system during the production process. Through the application of the methodology combined with VSM the results have improved compared to the traditional VSM method. This proves that this method is effective in overcoming takt time, cycle time, man power, and value-added ratio. Limitations of this research were also discussed, including that this research only focused on women's woven bottom products only on the production workflow. Kata Kunci: Agile System, Enhance Productivity, Garment Manufacturing, Lean Manufacturing, Value Stream Mapping.

Human–machine collaborative optimization method for dynamic worker allocation in aircraft final assembly lines

The allocation of workers with diverse skills on assembly stations significantly impacts the efficiency of aircraft final assembly (AFA). In a real-life assembly process, workers are allowed to move between multiple stations, to avoid bottleneck stations. The arrangement of worker movement is a practical issue coupled with the worker allocation, but is still ignored. This study formulates a dynamic worker allocation problem in AFA (dWA-AFA), focusing on the multiobjective joint optimization of worker allocation and worker movement. The trade-off between objectives depends on the human preferences that reflect assembly requirements. To address this, a human–machine collaborative optimization method (HMC-O) is proposed, involving a bidirectional collaboration: machine-to-human preference adaption, and human-to-machine experience support. Specifically, we design an adaptive dominance operator for integrating human preferences, and combine it with a two-stage nondominated sorting approach to generate initial optimization solutions. An experience-driven neighborhood search is further developed, which uses human experience to improve solutions. The proposed method is evaluated through two scales of real cases. It is observed the dWA-AFA significantly reduces the takt time, particularly by 14.21 % and 9.25 % in two worker-shortage scenarios respectively. Meanwhile, the HMC-O is competitive in terms of convergence and preference satisfaction for solving dWA-AFA.

Line Balancing Study Using Value Stream Mapping Tool on Lean Manufacturing: A Case Study in an Electronic Industry

XY Electronics, a leading international company in electronic components manufacturing, is confronting significant production constraints that adversely affect output, lead times, and operational expenses. This study examines the manufacturing line for product A using Value Stream Mapping to analyze process times and identify bottlenecks where takt times are exceeded. It focuses on areas surpassing production cycle times and aims to enhance line utilization through better line balancing and waste reduction. The results reveal that the header assembly, along with coplanarity and pre-testing 3, are major bottlenecks, which significantly impact productivity. By optimizing task allocation, refining workforce distribution, and employing cross-training, the production line efficiency improved significantly. In addition, strategic workforce reallocation and station optimization were crucial in addressing resource underutilization and enhancing overall operational efficiency

Productivity Improvement by Process Mapping in Sand and Casting Industry

Abstract: This research paper presents a comprehensive investigation into the efficacy of process mapping as a means of enhancing productivity within the sand and casting industry. Through the meticulous analysis of current state maps and the strategic development of future state maps, this study identifies and addresses inefficiencies in foundry operations, offering practical suggestions for the integration of new technologies, reduction of takt time, and alleviation of bottlenecks. Additionally, employing methodologies such as Time Study with Process Improvement, Rapid Upper Limb Assessment (RULA) analysis, and Rejection Analysis, this research provides a multifaceted approach to process optimization. By synthesizing empirical findings and industry insights, this paper not only underscores the importance of process mapping in enhancing efficiency but also offers actionable strategies to streamline operations and elevate productivity within the sand and casting sector.

Optimizing cutting speeds in a machining bottleneck stage in order to reach the takt time with the minimum machining cost

Optimizing cutting speeds in a machining bottleneck stage in order to reach the takt time with the minimum machining cost

Transforming Tablet Production in Indonesia with 66% Faster Manufacturing

This study addresses the high production costs of tablet products at PT. XYZ, a pharmaceutical company in Indonesia, due to long cycle and takt times. Using Causal Branching and KATA methods, data were collected over eight months through observations, interviews, and quantitative analysis. The study achieved a 43% reduction in reject foils from destripping, a 40% decrease in total cycle time, and a 66% reduction in takt time. These results highlight effective strategies for optimizing manufacturing processes and reducing costs in the pharmaceutical industry. Highlights: Cost Reduction: 43% reject foils, 40% cycle time reduction. Methodology: Used Causal Branching and KATA for problem-solving. Data Collection: Eight-month study with observations, interviews, quantitative analysis. Keywords: Tablet production, Cycle time reduction, Takt time optimization, Causal Branching, KATA method

Analysis of sales demand and production capacity to determine the need for direct labour

This study consists of meeting the sales demand using the existing production capacity in an electronic goods industry and thus determining the amount of direct labor (MOD) necessary to meet the needs of customers. Since obtaining the correct number of operators on a production line is extremely important in the pursuit of productivity and cost reduction. Therefore, using concepts such as takt time, cycle time and line efficiency and other information related to the product or products that will be assembled on a production line, it will be possible to quickly and assertively determine the number of operators that must serve directly the client's demand, thus guaranteeing productive efficiency and the correct application of labor resources using as assumptions the capacity and equipment already existing in the production line. Thus, based on the company's sales projection, it will be possible to determine month by month the number of operators, number of shifts and the appropriate volume to be produced to meet the requested demand.

Benefits of Femtosecond Laser 40 MHz Burst Mode for Li-Ion Battery Electrode Structuring.

In Li-ion batteries, ion diffusion kinetics represent a limitation to combine high capacity and a fast charging rate. To bypass this, textured electrodes have been demonstrated to increase the active surface, decrease the material tortuosity and accelerate the electrolyte wetting. Amongst the structuring technologies, ultrashort pulse laser processing may represent the key option enabling, at the same time, high precision, negligible material deterioration and high throughput. Here, we report a study on the structuring of electrodes with both holes and grooves reaching the metallic collector. Electrochemical models emphasize the importance of hole and line dimensions for the performances of the cell. We demonstrate that we can control the hole and line width by adjusting the applied fluence and the repetition rate. In addition, results show that it is possible to drill 65 µm-deep and ~15 µm-wide holes in nearly 100 µs resulting in up to 10,000 holes/s. To further reduce the takt time, bursts of 40 MHz pulses were also investigated. We show that bursts can reduce the takt time by a factor that increases with the average power and the burst length. Moreover, at comparable fluence, we show that bursts can shorten the process more than theoretically expected.

Lean Optimization of Batch Production in an Aluminium Company

This work investigates the optimization of a batch type of production and operational management in an aluminium company using a lean manufacturing system. The operation and production system of the case study company runs in various sectors, which led to waste in the system, hindering the company's ability to meet customer demand. Through operational data analysis and questionnaires, the team identified the types of waste generated by the case study company. Lean manufacturing techniques such as eight deadly wastes, Heijunka, takt time, 5S approach, quality tool management, value stream mapping, Kaizen, Kaban, Gemba, and top and bottom-level involvement were employed to manage the waste. The findings reveal defects in inventory, transportation, waiting times, and untapped ideas of employees, all of which significantly impact the company's performance. This allows for daily production of small batches of aluminium alloys (AA3001, AA3105, and AA3110) without issues, supported by the principle of pull production. Additionally, the application of Takt time results in a significant reduction of production time, leading to improved efficiency. The study also highlights the high interaction effect of transportation, defects, and inventory wastes on various production lines, such as the bogie fitting line paint line, and anti-intrusion. Among the lean manufacturing tools, Kaban, standard work, and 5S are identified as the most frequently used. The research findings provide valuable insights for manufacturing industry leaders to spot the performance gaps and enhance the application of lean manufacturing practices.

Improvement of Manufacturing Process Based on Value Stream Mapping: A Case Study

Value Stream Mapping (VSM) is a key tool in Lean Manufacturing (LM) that helps identify opportunities for process improvement. This research aims to propose an integrated method using LM tools (such as Kanban, VSM, Pareto chart, and Supplier Input Process Output Customer) and Arena simulation to improve the productivity of the production line through reducing lead time, inventory time, including Raw Material (RM) time and Work In Progress (WIP) time and enhancing Process Cycle Efficiency (PCE) ratio. To begin the process, a Pareto chart is employed to identify the main product of the organization. Subsequently, a current VSM is constructed to identify any waste in the production line. The Kanban tool is then used to propose appropriate remedies to improve the manufacturing process. To validate the efficiency of the production capacity in future VSM, Arena simulation is executed by determining Takt Time. Lastly, a future VSM is formulated based on the suggested improvements, and an appraisal is conducted to provide recommendations for prospective enhancements. A real case study of a furniture company in Vietnam is performed to demonstrate the effectiveness of the proposed method. The results reveal impressive benefits, including a 92% reduction in lead time and a corresponding 92% increase in PCE. Additionally, there is a substantial reduction of around 90% in WIP time, while RM time is completely eliminated, resulting in a 100% reduction. These findings highlight the efficacy of the proposed approach and the importance of VSM and other Lean tools in achieving process optimization.

Application Method of Value Stream Mapping to Increase Competitiveness in a Textile and Apparel Company

The textile and apparel sector is one of the most relevant and representative in Peru, due to its tradition and its contribution to the national economy. In recent years, however, it has had to become more competitive, largely due to the entry of international textile product suppliers into the local market. Therefore, companies that comprise this sector must adopt tools that will allow them to increase their productivity. In view of this situation, this research aimed to develop and implement an application model using Value Stream Mapping (VSM) in a textile and apparel company that manufactures garments for export, demonstrating at the same time that VSM is the best tool to visualize the entire supply chain in a single document. It also makes it possible to identify areas of opportunity, perceive the contribution of direct value to the products, distinguish forms of waste, and identify bottlenecks. The methodology adopted for the research is a case study, due to the use of various sources of information, including personal and documentary sources, and the conditions for its development. The results show the determination of the optimal takt time (1060.08 s), and the reduction in the lead time from 20.87 days in the current state map to 16.7 days in the future state map, thus contributing to the improvement of the company’s competitiveness.

Lean Manufacturing Implementation through Value Stream Mapping on Gold Products

The manufacturing process at UBPP Precious Metal Manufacturing Bureau involves many wasteful activities such as manual production records, lack of standardization and digitization, which can lead to lost time and non-conformities if something goes wrong. The purpose of the study is to identify and eliminate wastes in the manufacturing process using Value Stream Mapping (VSM) to achieve lean manufacturing. VSM approach to understand gold manufacturing mapped in the current state map and improvements applied to the future state map. The cycle time in the weight check, cleaning, press and engraving process for the gramasi variant is still above 7.2 seconds per pcs with a daily target of 9,000 pieces. Proposed improvements to eliminate waste such as equipment re-layout, rejuvenation of rolling equipment, punch, press, engraving can reduce cycle time below the targeted takt time.

Penurunan Lead Time Manufacturing Dengan Pendekatan Lean Manufacturing Studi Kasus Di PT. MKM

In the industrial world, it is very important to pay attention to the efficiency of production capacity where the manufacturing lead time for making shoe outsole is influenced by activities that are not value-added (Non Value Added) and activities that are not value-added but necessary (Necessary Non Value Added) in which there is some extravagance that occurs. These activities are in the form of temporary storage in the cooling room and the process of reworking defective products. The method used is Lean Manufacturing, the tools used are Value Stream Mapping (VSM) and Process Activity Mapping (PAM). VSM is used to identify activities that have cycle times exceeding takt time, followed by mapping the Activity Mapping process to analyze activities that are not Value Added. Based on the results of research from 4110 seconds, the process lead time of 3600 seconds is a non-value added activity. The rework process and material storage in the cooling room were identified as having the largest value contributing to lead time, so rework must be eliminated. the percentage of Process Cycle Efficiency (PCE) has increased. The reduction of the finished sheet material process is cooled to the cooling room and the rework process can save about 60 minutes of working time. Saving working hours can increase outsole production capacity so that productivity increases and targets are achieved.Keywords: Lead Time Manufacture, Lean Manufacturing, Value Stream Mapping, Prose Activity Mapping. Process Cycle Activity.

Increasing Line Efficiency By Using Line Balancing In A Steel Manufacturing Company

Line balancing using the Takt Time method is recognized as a modern tool forassisting businesses in reducing costs and increasing profits. It is possible for the enterpriseto smoothly produce the most optimal number of products by rational calculation andresource arrangement. This paper presents a case study on the application of line balancingby the Takt Time method in a steel factory in Vietnam. The methods selected for the studyinclude describing the current situation of the factory, applying Lean Manufacturingimprovement tools, applying modern equipment technology, and rearranging factoryresources, finally calculating Line Balancing metrics and implementing them in practice.According to the findings of the research, using the Takt Time line balancing methodprovides numerous benefits to the factory. The number of operators decreased by 9 people.The percentage of line balance increased by 22% from 77% to 99% and the efficiency ofline balance increased by 6% from 93% to 99%. In addition, the study also helpsVietnamese businesses have a more objective view of the application of Takt Time linebalancing in the future.

Lean improvement for pantograph jack production process using Value Stream Mapping

The objectives of this research are to study the current process and improve the production process of pantograph jack by using Lean manufacturing techniques. The Lean tool used is Value stream mapping (VSM). The study starts with collecting data from the upstream to downstream to create a Current-state VSM to identify wastes and problems. The first problem was the low efficiency of the production process due to the high lead time of 7 days 8 hours. The ratio of value-added time to the lead time was only 0.026%. The next problem was overproduction because the cycle time is 69.54 seconds/piece while the takt time is 140.15 seconds/piece, which is 46.62% of the takt time, resulting in the early stoppage of the production line to prevent over inventory of finished products. After identifying the problems, the next step is to define production process improvement approaches by creating a Future-state VSM. The tools for the improvement included the Kanban system, Supermarket, Line balancing, and Cellular manufacturing then a simulation model of both current and future states was created to compare the results before and after the process improvement. The result from the simulation shows that the total lead time was reduced to 4 hours 39 minutes or a decrease of 97.54% from the current state. The ratio of value-added time to the lead time was increased to 1.304%, which is 49.39 times more than before the improvements, and the cycle time was increased to 133.02 seconds/piece, which is 94.91% of the takt time.

Analisis Dan Usulan Perencanaan Tata Letak Pabrik Bagian Produksi Menggunakan Metode Systematic Layout Planning (SLP) Di PT.ABC

Good factory layout planning is one of the factors that can increase company productivity. Layout is a facility design, layout analysis, concept formation, as well as the embodiment of the system for making goods or services. Applying a good layout in a company can cut the time needed in a production process and also reduce the energy that must be expended by workers. This research was conducted at PT. ABC is part of the Drivetrain Unit Department located in the Bukit Indah City Industrial Area, Purwakarta, West Java. The object to be observed is the layout of the factory for the production of single part trunnion which is devoted to the seat trunnion sub-component. The research method used is quantitative method. Data processing used to solve problems at PT. ABC uses the Systematic Layout Planning (SLP) Method approach. The goal is to be able to optimize the existing layout and increase the efficiency and effectiveness of the productivity of the company's performance. The conclusion is that the current condition of the factory layout is quite effective because it can produce one trunnion product faster than the predetermined takt time. However, there are still some improvements in the layout of the factory and the production process. Researchers try to provide suggestions for the layout of the new factory and its production process. The result is that the suggested layout has a time that is 94 seconds faster than before. Keywords: Layout, Production, Productivity, Systematic Layout Planning