Lean-pull strategy in a re-entrant manufacturing environment: a pilot study for TFT-LCD array manufacturing

Yang, Taho; Hsieh, Chiung Hsi; Cheng, Bing Yuan

doi:10.1080/00207540903567333

Cited by 33 publications

(11 citation statements)

References 36 publications

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“…A simbologia do VSM foi desenvolvida de modo a facilitar a identificação dos desperdícios e suas fontes, o que reforça a sua contribuição para com os objetivos da Produção Enxuta (Rother;Shook, 2005;Cottyn et al, 2011;Lu et al, 2011;Yang et al, 2011). No Brasil difundiu-se o uso da sigla TRF, iniciais de troca rápida de ferramentas, como tradução do Single minute exchange of die (SMED).…”

Section: Ferramentas Da Manufatura Enxuta (Vsm Smed 5s)unclassified

Princípios Da Manufatura Enxuta Como Proposta Para Arranjo Físico Na Indústria De Transformação De Termoplásticos

et al. 2015

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A redução de perdas e o aumento dos ganhos se configuram como um dos grandes objetivos das organizações, que por meio da otimização dos processos e consequente agregação de valor, revela a necessidade de investimentos por parte das empresas, garantindo assim, a melhoria contínua de seus processos. O Presente estudo caracterizado como uma pesquisa-ação tem como objetivo desenvolver uma proposta de arranjo físico, por meio da aplicação dos conceitos básicos de manufatura enxuta para uma indústria do setor de transformação de termoplásticos. Os resultados obtidos demonstram a melhor opção de arranjo físico, considerando o tipo de processo da empresa, bem como a estratégia de flexibilidade da mesma. Ainda se apresenta a análise de perdas com o atual arranjo físico, sendo o ponto de partida para a proposta do novo layout, onde estimou-se ganhos no fluxo do processo produtivo como também a redução das sete perdas em cada parte dos processos de manufatura, os quais podem ser adquiridos com a efetiva implementação da proposta de arranjo físico.

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Section: Ferramentas Da Manufatura Enxuta (Vsm Smed 5s)unclassified

Princípios Da Manufatura Enxuta Como Proposta Para Arranjo Físico Na Indústria De Transformação De Termoplásticos

et al. 2015

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“…The second step is a pacemaker process selection and leveling of production by both volume and product mix [33]. The pacemaker process must be the only scheduling point in the production system and dictates the production rhythm for the rest of the system, where the pace is based on a supermarket pull system further upstream from this point, as well as First In First Out (FIFO) systems further downstream [34][35][36][37]. According to the theory of constraints (TOC), one of the most important points to consider is the bottleneck.…”

Section: Group Technology Approachmentioning

confidence: 99%

The Integration of Group Technology and Simulation Optimization to Solve the Flow Shop with Highly Variable Cycle Time Process: A Surgery Scheduling Case Study

Wang

Chan

Yang

2014

Mathematical Problems in Engineering

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Surgery scheduling must balance capacity utilization and demand so that the arrival rate does not exceed the effective production rate. However, authorized overtime increases because of random patient arrivals and cycle times. This paper proposes an algorithm that allows the estimation of the mean effective process time and the coefficient of variation. The algorithm quantifies patient flow variability. When the parameters are identified, takt time approach gives a solution that minimizes the variability in production rates and workload, as mentioned in the literature. However, this approach has limitations for the problem of a flow shop with an unbalanced, highly variable cycle time process. The main contribution of the paper is to develop a method called takt time, which is based on group technology. A simulation model is combined with the case study, and the capacity buffers are optimized against the remaining variability for each group. The proposed methodology results in a decrease in the waiting time for each operating room from 46 minutes to 5 minutes and a decrease in overtime from 139 minutes to 75 minutes, which represents an improvement of 89% and 46%, respectively.

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“…In the past studies, various tools and techniques of the lean production system that aim to improve the operational performance of industries have been discussed in academics (Modarress, Ansari, and Lockwood 2005;Rubio and Corominas 2008;Lu, Yang, and Wang 2011;Yang, Hsieh, and Cheng 2011;Saurin, Rooke, and Koskela 2013).…”

Section: Introductionmentioning

confidence: 99%

Implementing lean standard work to solve a low work-in-process buffer problem in a highly automated manufacturing environment

Lu¹,

Yang

2014

International Journal of Production Research

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Over the past few decades, a considerable number of studies have been reported on assembly lines or less automated factories. Little attention has been given to implementing lean tools to a highly automated manufacturing environment. It is, therefore, necessary to make a more highly automated factory lean by considering both the manufacturing system variability and demand uncertainty. The purpose of this paper is to propose an effective lean tool to help practical lean participants successfully implement lean practices in a highly automated manufacturing environment. This study presents an example of how lean standard work is implemented and the throughput of a pacemaker workstation is improved by solving the low work-in-process buffer problem. A practical case from a photovoltaic module process with a semi-automated production line is used to illustrate the proposed method. The implementation results are promising. They showed a 37.5% labour reduction prior to the pacemaker workstation and a 304.7% increase in the daily throughput at the bottleneck workstation.

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Lean-pull strategy in a re-entrant manufacturing environment: a pilot study for TFT-LCD array manufacturing

Cited by 33 publications

References 36 publications

Princípios Da Manufatura Enxuta Como Proposta Para Arranjo Físico Na Indústria De Transformação De Termoplásticos

Princípios Da Manufatura Enxuta Como Proposta Para Arranjo Físico Na Indústria De Transformação De Termoplásticos

The Integration of Group Technology and Simulation Optimization to Solve the Flow Shop with Highly Variable Cycle Time Process: A Surgery Scheduling Case Study

Implementing lean standard work to solve a low work-in-process buffer problem in a highly automated manufacturing environment

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