Various case studies of implementation of lean manufacturing at industries

Lean Management Case Studies

In the end, the company deemed current equipment sufficient to meet not only present demand but also forecasted sales expectations for quite some time.

A special turntable was constructed to allow for easier lifting of heavy parts.

Case Studies on the Implementation of Lean Manufacturing in the Automotive Malaysian Companies

The company earned global recognition for its use of Six Sigma when one project team earned the Bronze Award in the International Team Excellence Award competition. A comprehensive schedule was created, complete with a check and balance system, to ensure all components were being adequately cared for and maintained.

Changing from one shift to another created long periods of low or stopped production. Many potentially destructive and completely debilitating defects were discovered and corrected. Quality checks for 1st articles that could take an hour or more were prioritized and all staff and equipment were subordinated to their rapid completion.

Time spent transporting parts is now spent processing products. All of these duties were performed while the operator from the previous shift continued to run the equipment or completed assigned work processes.

Quality Progress, January The company had spent many months attempted to make the transition to lean on their own, with minimal success. Only operation adds value to the product and other functions such as inspection, transportation, and delays of a permanent or temporary nature are waste and should be eliminated.

Defects caused by packing and transporting parts are now almost completely eliminated. This posed a problem: This gain was sustained and later improved upon after a re-layout of the area in a Blitz Event.

This added approximately 5 hours of additional up-time per machine, per day. They needed to reduce setup times and WIP work in process inventory. In another division of this company, we trained TPM facilitators to help teach and implement the same program throughout the remaining divisions, with impressive results and many successes.

These were products that would eventually be as long as feet and consume a considerable amount of production time and materials. To excellent the Lean manufacturing, companies are required to satisfy customer needs, improve the manufacturing process, and increase their flexibility.

Understanding recent changes not only in customer requirements but also in customer processes proved to be key to the solution. Strict capacity loading rules were put in place to assure that we did not overload the mill. Brief all-employee meetings were held on all shifts. Return to List Foundry: Single Minute Exchange of Die methods, we reinvented the entire operation and created a procedure that minimized downtime.

We then level-loaded these production areas via KanBans and then established new procedures.

Lean Management Case Studies

Return to List Custom Machining: WIP and finished goods inventories were brought under control, and no additional production staff were hired. Staging procedures and preparation checklists were instituted to maintain quality, process integrity and follow-through. In another division of this company, we trained TPM facilitators to help teach and implement the same program throughout the remaining divisions, with impressive results and many successes.

Machine downtime and its associated costs impacted the bottom-line profitability of this well established, full-service machining operation. We obviously needed to change the balance of our shifts.

They faced a very real risk of losing some critical accounts. Lead times and lot sizes were cut. Natural work teams planned and participated in their area re-layouts. In less than six months: The easiest way to accomplish these conflicting objectives is to keep a huge pile of inventory in front of every unit so that they can put together an optimal run schedule.

Lean Manufacturing has been widely adopted in various business and industries worldwide. After implementing the new procedures, all setups and changeovers were completed in under 30 minutes regardless of complexity.

Single Minute Exchange of Die methods, we reinvented the entire operation and created a procedure that minimized downtime. With every step made toward creating a Lean environment, campus layout at this successful foundry became an increasingly important issue. implementation of lean principles and to develop different strategies to eliminate waste.

2. Brief Literature review. Lean manufacturing whish derived from Toyota Production System is a philosophy for structuring, operating, controlling, managing, and continuously improving industrial production systems (Sahoo et al.

Case Studies/Results

). Lean Manufacturing in Action: 3 Lean Implementation Case Studies by [user not found] | Jul 10, A successful Lean implementation is one of the most trying and challenging things a. A case study of lean, sustainable manufacturing 12 G. Miller; J.

Pawloski; C. Standridge Manufacturing and quantitative analysis performed using tools such as mathematical optimization and discrete event simulation. In this regard, validation evidence for two premises is sought through a case study at a small furniture production company.

Lean manufacturing is a known principle used in today’s industries to eliminate various hidden wastes that do not add value to the finish product.

Lean Manufacturing in Action: 3 Lean Implementation Case Studies

Lean concept has many advantages which have helped many companies over the years to stay more competitive in global and national business.

Implementation Of 5S Methodology In The Small Scale Industry: A Case Study R. S. Agrahari, P.A. Dangle, turnonepoundintoonemillion.comatre Abstract: 5S is a basic foundation of Lean Manufacturing systems. It is a tool for cleaning, sorting, organizing and providing the necessary.

A case study on implementing lean ergonomic manufacturing systems (LEMS) in an automobile industry Srinivasa Rao P1, Malay Niraj2 1Department of Mechanical Engineering, NIT Jamshedpur, Jamshedpur, India 2Department of Mechanical Engineering, NIT Jamshedpur, Jamshedpur, India E-mail: [email protected]om Abstract: Lean manufacturing is a business strategy developed in Japan.

Various case studies of implementation of lean manufacturing at industries
Rated 0/5 based on 51 review
VIBCO Industrial Vibrators Blog