An ECRS-based line balancing concept: a case study of a frozen chicken producer

Abstract

Purpose – The purpose of this paper is to improve the productivity of a large-sized frozen chicken manufacturer in Thailand. It analyses the production process based on work study principles and identifies the bottleneck operation. It develops three models for the chicken preparation process. Design/methodology/approach – First, analyse the current production system by collecting the cycle time of all operations in the production process based on work study principles. Then, design the production network and identify the bottleneck operation. After that, three methods – based on line balancing (LB), theory of constraints, and JIT concepts or ECRS (eliminate, combine, rearrange and simplify) – are proposed and implemented in the actual production line. Findings – With the ECRS concept, the authors implement combine by combining two stations into one station, such as handling and weighing, or weighing batter and mixing it with chicken. Then, Simplify is implemented at job E, or transporting chicken using a cart instead of walking. This method can improve the cycle time and reduce the number of employees. It can increase the line efficiency by up to 94.20 per cent, reduce the number of employees by 14 persons, and reduce the labour cost by 356,160 baht/year. Originality/value – Most agro-industry manufacturing processes are labour intensive. Thus, production LB can help increase productivity and reduce costs. The authors found that the case study company designed the production line without aligning it with the production network. A simple improvement can be made by adjusting the sequence of the work. In addition, the current production line was not lean. Implementation of the ECRS concept to improve production can reduce the waiting time and simplify the job.

Part Transportation Improvement in Warehouse of an Automotive Factory

“…The new operations method aims to reduce time to find parts storage locations for keeping parts in the preparation area was developed by adapting the ECRS technique of the Lean concept [7]. The number of part numbers per storage cycle in the preparation area was reduced.…”

Labour Productivity Improvement in an Automobile Component Manufacturer Machine Shop using Lean Tools

“…7 : Radial drilling Combine technique is used to increase the productivity. [3] After combining all the four operations mentioned above in a new three axis machine the old four machines are removed from the line. Thereby the throughput time is reduced and it gives more free space in the line.…”

“…combine job A and B which reduces the manpower. [3] For productivity improvement in a drinking water production plant, equipment has been used to combine the product at the packing stage for the ease of putting film on the water bottle, which has reduced the cycle time and increased the productivity. [4] For manpower reduction in a pasteurized milk manufacturing organisation, job done by two workers was reduced to one.…”

Design of Intelligent Logistics System Based on JIT Material Distribution Plan

“…Therefore, the maximum delivery time is 8.4min to ensure the normal production of the production line. After the unpacking process has been canceled, the picking and feeding procedures are analyzed in accordance with the 5W2H questioning technique and the ECRS principle [7][8]. The picking process has been canceled.…”