Algorithm to Use Some Specific Lean Manufacturing Methods: Application in an Industrial Production Process

Abstract

Lean Manufacturing includes an ensemble of methods to analyze and continuously improve the functioning of manufacturing systems. The research presented in the literature highlights the fact that these methods are, on their own, in a process of continuous improvement as tools, being used in different ways, for different production systems. The paper presents an algorithm that facilitates the choice of the performance evaluation method, and the choice of the method of improvement that needs to be implemented for an efficient analysis and for a continuous increase of the manufacturing system performance. In addition to these, for the JobObservation and 5S methods, chartflows are proposed and specific tools are developed (questionnaires, forms etc.) that are meant to facilitate the implementation and to focus (guide) the user in the direction of improvement for the analyzed process. The algorithm, techniques, and tools developed in this research were used in a case study that took place in a production system “plastic injection”. Thus, a series of important improvements were made in the functioning of the production system, consisting of the reduction of production area, decrease of cycle time, decrease of the number of operators, stabilization, standardization, and securing of the work processes. All this has led to the improvement of several key performance indicators (KPIs) of the production system. The analysis of the investment in the reorganization of the production system in relation to the obtained gains shows a payback of approximately 1 month, proving the efficiency of use in such a form of the Lean Manufacturing methods.

Implementation of Lean Instruments in Ceramics Industries

“…The ceramics industry is characterized by a very wide range of products and technologies. Based on the literature [4,8,19] and own research [33,34], it can be concluded that the implementation of Lean is best in enterprises with a fixed assortment of production and large production series, e.g., the production of ceramic tiles [32], ceramic blocks or electrical insulators [35]. Against this background, manufacturers of ceramic accessories have a significantly difficult process and implementation industry related to a large range of products produced in small production batches that often change in terms of volume, where the critical point determining the effectiveness of the entire process is the forming stage.…”

“…Therefore, entrepreneurs need appropriate knowledge for the solutions they implement to bring the expected results. Each industry is characterized by individual conditions in terms of production technology, organization and work techniques [17,18,19,20]. It is practically impossible to develop a uniform improvement methodology for all production companies.…”

Algorithm for Process Innovation by Increasing Ideality

“…There are many cases where the improvement rate is much more significant, but it seems that these cases are not as often. These findings are based on the research of other authors such as [57][58][59][60][61][62][63][64][65][66][67][68]. Based on a comparison of the classical indicators, the change achieved in the process is slightly above average.…”

Development of a Multi-Criteria Design Optimization Methodology for Automotive Plastics Parts

“…The methodology has a set of tools, as shown on the left side of the schema in Figure 4 , and a “discrete event” utilization strategy and documents, as shown on the right side of the same schema. The aim of the methodology tools is to be the knowledge capture base, which is oriented towards long-term profitability based on “incremental” development in a comprehensive and continuous improvement way [ 41 ]. The discrete event strategy and documents are defined to take maximum advantage of the methodology tools in every application loop, and to help to document the analysis, calculations, and decisions carried out in each event.…”