Applying Lean Techniques to Reduce Defective Products: A Case Study of an Electrode Manufacturing Company

Huarhua-Machuca, A.; Nunez-Ponce, Victor; Altamirano, Ernesto; Alvarez-Merino, J. C.

doi:10.1109/ieem44572.2019.8978865

Cited by 3 publications

(2 citation statements)

References 3 publications

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“…SMED was used in integration with other lean tools such as KANBAN, 5S, and TPM to optimize and reduce variability in changeover times, increasing the packaging capacity and improving the OEE by 25%. Huarhua-Machuca et al [26] proposed a combination of 5S and SMED to reduce the number of production defects in an electrode manufacturing company using simulation. This proposal reduced the number of defectives by 11.23%, thus, improving the level of quality and yielding economic benefits.…”

Section: Literature Reviewmentioning

confidence: 99%

Improving Overall Equipment Effectiveness (OEE) of Extrusion Machine Using Lean Manufacturing Approach

Haddad¹,

Shaheen²,

Németh³

2021

Manufacturing Technology

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Providing products with higher quality and lower prices is considered to be a competitive advantage for the industrial firms over competitors. This main challenge can be achieved by minimizing the overall production costs and operational time. Lean manufacturing provides many tools and techniques to identify and eliminate wastes and to reduce costs in production systems. In this paper, the single minute exchange of die (SMED) technique is used as a lean manufacturing approach in a leading Palestinian aluminum and profiles company. SMED was implemented through real experimental procedures applied to the extrusion line processes to investigate its effect on decreasing the setups time and improving the Overall Equipment Effectiveness (OEE) of the extrusion machine, in addition to introduce a guide for practitioners to improve the extrusion process of dies exchange in similar industries. Overall, the successful implementation of SMED resulted in an increase of OEE by 3.26% as the consequence of the increase of machine availability by 4.86%.

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Section: Literature Reviewmentioning

confidence: 99%

Improving Overall Equipment Effectiveness (OEE) of Extrusion Machine Using Lean Manufacturing Approach

Haddad¹,

Shaheen²,

Németh³

2021

Manufacturing Technology

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“…For massproduction manufacturers, the key challenge was to retain price competitiveness and production efficiency. As a result, it has become one of the primary motivations for automakers to focus on price, product quality, product differentiation, and delivery performance at the same time [5]. To support modern manufacturing systems, producers must aim to create a series of processes that allow them to focus on creating value while removing any distractions that slow down output [6].…”

Section: Introductionmentioning

confidence: 99%

SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software

Qayyum

Zuki

Nelfiyanti

et al. 2021

IJAME

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The automotive industry is one of the most advanced industries in the world. The demand for vehicles keeps increasing over time, mainly influenced by technology’s sophistication and impressive designs. This research is focusing on the production performance of the stamping process in Malaysia’s automotive industry. The main issue observed and evidenced in data collected from industry players is that an unacceptably long time is taken in the die/tooling change process, which grossly affects the planned production output. The most significant direct impact on this situation is the increase in operating costs due to additional time taken to meet the planned production output. Therefore, this research aims to establish a new framework that can optimise the efficiency of the dies changeover process, which could lower the overall production cost, which could partially transfer the saving to the consumers. The study was conducted in two stages; the first is on data collection correlates with the automotive stamping premise to create a simulation procedure, and the second is to analyse the current production output using WITNESS simulation. These simulated output data have later been compared to the actual industrial data. Using a systematic dies changeover process, a new alternative framework was proposed. The framework combined single minute exchange of die (SMED), lean tools and simulation to become an integrated single minute exchange of die (ISMED). It shows that the proposed method decreased the changeovers processes from the initial of 1509.5 seconds to 750.75 seconds, then further reduced to 569.75 seconds, with the nett time reduction of 62.2%. The result shows that the daily production output has increased gradually from 1100 pieces to 1500 pieces, further increasing to 2145 pieces. As evidenced in analytical data, it is believed that this new framework can strengthen the total output in the manufacturing process, especially in the manufacturing of automotive stamping parts.

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Introducing Lean practices through simulation: A case study in an Italian SME

Frecassetti

Kassem

Kundu

et al. 2023

Quality Management Journal

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Applying Lean Techniques to Reduce Defective Products: A Case Study of an Electrode Manufacturing Company

Cited by 3 publications

References 3 publications

Improving Overall Equipment Effectiveness (OEE) of Extrusion Machine Using Lean Manufacturing Approach

Improving Overall Equipment Effectiveness (OEE) of Extrusion Machine Using Lean Manufacturing Approach

SMED Simulation in Optimising the Operating Output of Tandem Press Line in the Automotive Industry using WITNESS Software

Introducing Lean practices through simulation: A case study in an Italian SME

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