Implementation of Production Process Standardization—A Case Study of a Publishing Company from the SMEs Sector

Abstract

This paper reports a case study using a standardization process for increasing efficiency and a better optimization of resources in a printing company with 150 operators having manual and mechanical tasks in the box assembly department along with four production lines. The current capacity is 350 boxes per day, while the demand is 650 units, where the company is expected to pay large sums for overtime. Using work standardization, studying worker movements, timing, and workstations redesign, the main goal was to increase the efficiency and productivity indexes. After applying those tools, the inefficient movements in operators decreased from 230 to 78, eliminating 66% of the unnecessary movements, as well as the standard time in a workstation decreased from 244 to 199 s (18.44%) per each assembled box, and the production rate increased by 63.2%, that is, 229 units per assembly line a day, where overtime was reduced to zero.

Implementation of Integrated Autonomous Maintenance and Standard Work to improve the productivity in post-harvest production: Case study of a Peruvian coffee farm

“…Existen diversas herramientas Lean Manufacturing que permiten la eliminación de desperdicios y el desarrollo de un sistema de producción esbelto tales como Standard Work, 5S, Kaizen y VSM [10]. Standard Work es una herramienta que minimiza la variabilidad de los procesos que realizan los operarios y también elimina las actividades que no agregan valor al proceso [11] [12]. Sin embargo, la aplicación de esta metodología presenta deficiencias en el caso de estudio, ya que no considera el nivel de conocimientos de cada trabajador y la variabilidad de las mejores prácticas para desarrollar los procesos.…”

“…También se implementó en una empresa productora de muebles, y luego de aplicar la herramienta, los tiempos de fabricación se redujeron y por consecuencia la empresa aumentó su productividad en un 33% [9]. Por último, en una empresa productora de cajas de cartón se adaptó esta herramienta, reduciendo los movimientos innecesarios dentro de la línea de producción y los productos defectuosos por errores de manipulació n, lo g ran do un incremento de producción del 45% y reduciendo los sobrecostos por hora hombre que se utilizaba al momento de realizar los reprocesos de los productos [12].…”

Application of Lean Tools to Reduce Waste in an Organic Mango Exporting Company: An Investigation in Peru

“…In addition, it allows the elimination of operations that do not generate added value to the product or service; consequently, productivity and efficiency increase significantly in the process [13]. The correct implementation of this tool has been able to present several advantages in the organizations, such as the reduction of bottlenecks and waiting times, allowing to increase the production [14]. Also, the standardization of work allows reducing the cycle times of a product and the errors number, increasing the production rate [15].…”

Special Issue on Performance Measurement and Optimization for Sustainable Production Processes Improvement

“…Realyvásquez-Vargas et al [10] analyzed a case study about production process standardization implementation for better optimization and increasing efficiency. Kim [11] tried to find the optimal solution of production planning to reduce production cost in furniture production process using Korean furniture industry dataset.…”