Implementation of lean tools and techniques in an ethical papers production industry

Globalization breeds increasing competition. In today's dynamic climate, lean thinking has been found a promising business continuous improvement strategy for improving quality while reducing product cost and delivery time. However, its implementation has dynamic nature of challenges that varies from industry to industry and country to country, necessitating a specific framework by taking all stakeholders onboard. This study aims to propose a lean implementation framework to reduce defects and waste to improve the performance of the metal casting industry. The structure of the framework has been divided into three phases namely the lean conception phase, lean implementation phase, and lean sustainability phase. The proposed framework integrates the six sigma DMAIC methodology with lean tools and techniques to reduce defects and achieve performance improvement. A solid cast software has been used as a computer-assisted casting simulation tool to perform the analysis of defects within the casting. Further, the proposed framework is demonstrated and validated by employing a real-time case study that was manufactured using the sand casting process. The obtained results show remarkable improvements in poured metal weight (33.3%), mold weight including gating system (40%), casting yield (24.56%, rejection rate (90%), and financial saving (24.63%). As a result of analysis of percentage improvements data, the proposed framework can provide the practitioners with a standard roadmap and motivate the casting industries to implement lean for performance improvement through organizational change. Through the effective application of the lean implementation framework, quality enhancement has been demonstrated. INDEX TERMS Lean implementation framework, metal casting industry, six sigma-DMAIC, computerassisted simulation

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Integration of lean and green manufacturing to speed up the automotive parts production process for sustainability orders from customers

Kurnia,

Sulaeman,

Pasha

2024

j. sist. manaj. ind.

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Fulfilling orders from the automotive industry customers is a necessity. Problems arising from product delivery to customers are due to production delays, decreased production yields, and environmental pollution caused by production waste. The production process often experiences wasted time producing four-wheeled vehicle spare parts and a high percentage of production defects. This research aims to reduce production process time, provide solutions to reduce waste, and balance production stock according to customer orders. This research uses the Lean Manufacturing (LM) approach with the Value Stream Mapping (VSM) method combined with the Green Manufacturing (GM) approach with the Just in Time (JIT) and Kanban methods. This research resulted in the production process time for four-wheeled vehicle spare parts decreasing from 11.0 days to 4.5 days, meaning a decrease of 159%. It affected production results, increasing from average monthly production of 42,917 pcs to 59,990 pcs, meaning an increase of 128%. Meanwhile, the shipment plan target has been achieved at 96% of the plan order. Meanwhile, Turn Over Inventory (TOI) results are under 30 days, so customer order continuity exists.

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Implementation of lean tools and techniques in an ethical papers production industry

Cited by 4 publications

References 16 publications

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Lean Implementation Framework: A Case of Performance Improvement of Casting Process

Integration of lean and green manufacturing to speed up the automotive parts production process for sustainability orders from customers

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