Papers by Keyword: 5S

Abstract: In recent years, the textile industry has increased its exports compared to previous years and produces thousands of jobs per year. However, some manufacturing companies in the textile industry experience low efficiency, such as the current textile company under study associated with unplanned machine downtime and idle time. In this sense, this study aims to promote the capacity, productivity, and efficiency of textile companies that manufacture garments. Therefore, a Lean Maintenance model supported by the integration of Lean Manufacturing instruments and techniques such as TPM, 5S, Kaizen is proposed in order to improve machine availability and quality through management metrics. After the implementation of the proposed tool integration, the activities of the operations were standardized, an increase in efficiency was generated, and a favorable change in maintenance metrics was achieved.

Abstract: Currently, SMEs are exposed to economic losses due to inadequate internal management, one of the main being "Process Management". This brings consequences to the entire flow of production and sales of the company in a directly proportional way. Also, without the necessary material to produce, there are no products to sell, affecting the level of defective and customer satisfaction. Therefore, the motivation of the article is to design the management by processes and analyze the causes of the increase in the levels of defective in the SMEs of the Peruvian textile sector. To address this challenge, it aims to reduce the level of defective products from 8% to 5% optimal as indicated by the technical gap. The solution integrates Lean tools such as the 5S tool, Autonomous Maintenance and Process Standardization to improve and increase quantitative and qualitative indicators in the company. In addition, the PDCA cycle was integrated as a fundamental contribution and link to the proposed solution model and also as a mechanism to support sustainability that will be implemented and that allows the continuous improvement of processes and product quality, which will increase the competitiveness and profitability of the company in the market.

Abstract: In the context in which spare parts trading companies are becoming increasingly competitive, the level of service is essential to be able to compete in the market. This indicator is affected by on-time deliveries, which are a key factor in meeting customer demand, as this determines customer satisfaction and thus has an effect on the company's profitability. For a company to deliver its products on time, the warehouse processes must work efficiently, making the picking process one of the most critical of them. It must also run a proper inventory procurement process in order to have stock on hand to fulfill customer orders. This case study focuses on increasing the level of service in a company that sells spare parts for mining, which was found to have a low service level of 66.1%, in contrast to the recommended level for the sector, which is 85.9%. Therefore, the implementation of the 5S methodology, Systematic layout planning, demand forecasting, and cycle counting are proposed as tools to solve the root causes of the problem. The main results indicated a reduction in picking times of 36.70%, an increase in demand forecast accuracy of 13.45%, and an increase in Inventory Record Accuracy (IRA) of 5.42%.

Abstract: In recent engineering practices, the manufacturing industries are more technically able to produce product with high quality to desire the customer needs. For accomplishing customer needs many lean tools are used to improve the methods of manufacturing practices in industries. The aim of this research work is enhance the productivity of spool casing assembly used in horn armature core per shift by using method study, time study and VSM. Cycle time for each operation of the product is determined by time study and the value added, non-value-added activities and transportation wastes occurred in the current state process identified and plotted in the current state VSM. The future state VSM was developed to reduce unnecessary wastes such as transportation, inventory, waiting which occurred in the current state VSM. Both current and future state time study are simulated using Flexsim simulation software. From the observed results it was found that, P3 and P5 model productivity was improved by about 5.5% and 6.5% respectively after implementation of appropriate lean tools.

Abstract: The development of more effective management techniques has become essential for the improvement of working conditions within the company. The construction industry is characterized by unpredictable and fluctuating construction processes which increase the level of risk of accidents. In this context, this work aims at conducting a synthesis of the most reliable research in the field of safety management in order to study the contribution of Lean Construction practices in the promotion of safety. The study evaluates the potential effectiveness of Lean Construction tools such as (Last Planner System, Visual Management, 5S, Error-proofing) in promoting the safety on construction sites. This study shows that lean construction tools have a great potential to improve the safety performance. Several Lean Construction practices such as the correlation between scheduled tasks and the ability of the staff working on site, choosing of working methods in compliance with safety requirements, the incorporation of visual tools, and the Simplification of workflow could minimize the risk of accidents and promote the worker safety through minimizing hazards, motivating people involvement in the planning phase and preventing human errors.

Abstract: The growing context of globalization permanently increases pressure on the construction companies to improve their performances in order to resist to the constraints of competitiveness in the international market. It has become ineluctable to look for introducing a new alternative capable of bringing creative improvement to the traditional production system. This paper will relate mainly to the most relevant management techniques in the construction industry, and more specifically, the lean construction concept. Initially, we will determine the main characteristics of the construction industry compared to the manufacturing industry according to three levels: on-site production, one of a kind projects, and complexity. Subsequently, we will focus our attention on the main sources of waste in the construction industry. Finally, a rigorous comparative study will be carried out to show the contribution of the lean construction tools in the promotion of traditional construction especially at the level of the following factors: Creating value and eliminating waste; Planning and mutual coordination; Site organization. Lean construction as Last Planner System (LPS), Value Stream Mapping (VSM), Just-in-Time philosophy, Visual management (VM) and 5S have shown a great ability to improve the traditional production system through waste reduction, encouraging people involvement, ensuring a pull flow production, and promotion of a continuous improvement philosophy.

Abstract: Value stream mapping has the reputation of uncovering waste in manufacturing, production and business process. This helps in identifying and removing or streaming value added steps and eliminating non value added steps. In this study the process was analyzed to find an opportunity to drastically reduce the number of actions and to simplify the same. By reducing waste the proportion of value adding time increases in the whole process and the process throughput speed could also be increased. This makes the redesigned process more effective and more efficient. The reengineered process was flow charted in its future state with process steps and information flows re-engineering, simplified and economized. The current layout was analysed to identify and eliminate the non value added activities through lean tools like 5S, VSM and line balancing in a manufacturing industry. From the observed results, it was concluded that the non value added time could be reduced by about 13% while the process cycle efficiency could be increased by about 10%. Virtual simulation was conducted to verify and validate the existing situation as well as to propose the results and the effectiveness of lean principles in a systematic manner with the help of ARENA.

Abstract: A study on Autonomous Maintenance (AM) implementation was conducted for CNC machine at automotive components manufacturing line in order to identify and measure equipment losses related to availability, performance and quality rate. These values were used to determine the overall equipment effectiveness (OEE) of the manufacturing line before and after AM implementation. The project started with AM team formation before it was continued with 5S activities and fuguai (abnormality) detection and restoration. Kaizen was used for continuous improvement to restore deteriorated parts and components of the machine. Autonomous Maintenance standards such as cleaning, lubricating and inspection were developed. The AM team members consistently followed the operator maintenance standards to ensure that machine is always in good working condition. The OEE results were taken daily after AM implementation and compared with the data before the implementation. The average OEE result shows significant improvement from 65.8% to 80.4% after the AM implementation. However, the result still did not achieve the company’s target. The main reason was because the machine was very old, which almost reaches deterioration stage according to the bath tub curve. Some recommendations are suggested as to push the OEE value closer to the company’s target including a review on other pillars in Total Productive Maintenance (TPM).

Abstract: Various Lean developments and related matters have been accomplished [1-7, etc.]. This paper attempts to stress on several main methods of Lean culture applied in Zentiva Romania pharmaceuticals production plant, such as: +QDCI, SMED, 5S, etc. A systematic analysis and development of adequate actions for solving the considered critical problem have been accomplished, based on the Lean manufacturing principles. The Lean tools applied in Zentiva Romania are being used to identify and eliminate wasteful steps in products and processes, increase the manufacturing capability and reduce cost, in order to remain competitive on the market, deal with fast transfers of new products and technologies, etc. An important result is the emphasize of the Lean methods implementation benefits, such as greater productivity, improved lead times, elimination of waste, innovation stimulation, safer work environment, better monitoring of the outputs etc.

Abstract: In this paper, by studying a lot of advanced electronics manufacturing enterprise production management mode, put forward a basic structure of complete quality control system, and the elements of this structure is introduced in detail. Practice has proved that These practices on the establishment of "stable process" and improve the "product quality" has a very effective role.