Methodology for improving production flows on an assembly line

Niţu, Eduard; Gavriluţă, Alin; Belu, Nadia; Gavriluță, C. A.

doi:10.1088/1757-899x/968/1/012014

Cited by 3 publications

(2 citation statements)

References 11 publications

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“…To facilitate the understanding of the efficient application of the VSM evaluation method and of the TPM improvement methods, Kanban, Jidoka, Poka-Yoke, Hoshin, and Kaizen Circles in a production system, within the mentioned project, were developed and tested on platforms, which are detailed in [34][35][36].…”

Section: Algorithm For Applying Lean Manufacturing Methodsmentioning

confidence: 99%

Algorithm to Use Some Specific Lean Manufacturing Methods: Application in an Industrial Production Process

2021

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Lean Manufacturing includes an ensemble of methods to analyze and continuously improve the functioning of manufacturing systems. The research presented in the literature highlights the fact that these methods are, on their own, in a process of continuous improvement as tools, being used in different ways, for different production systems. The paper presents an algorithm that facilitates the choice of the performance evaluation method, and the choice of the method of improvement that needs to be implemented for an efficient analysis and for a continuous increase of the manufacturing system performance. In addition to these, for the JobObservation and 5S methods, chartflows are proposed and specific tools are developed (questionnaires, forms etc.) that are meant to facilitate the implementation and to focus (guide) the user in the direction of improvement for the analyzed process. The algorithm, techniques, and tools developed in this research were used in a case study that took place in a production system “plastic injection”. Thus, a series of important improvements were made in the functioning of the production system, consisting of the reduction of production area, decrease of cycle time, decrease of the number of operators, stabilization, standardization, and securing of the work processes. All this has led to the improvement of several key performance indicators (KPIs) of the production system. The analysis of the investment in the reorganization of the production system in relation to the obtained gains shows a payback of approximately 1 month, proving the efficiency of use in such a form of the Lean Manufacturing methods.

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Section: Algorithm For Applying Lean Manufacturing Methodsmentioning

confidence: 99%

Algorithm to Use Some Specific Lean Manufacturing Methods: Application in an Industrial Production Process

2021

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“…In this study, the DOJO method was applied according to the methodology presented in Figure 4 [41]. The indicators used to evaluate the training performance of the participants are as follows:…”

Section: The Operator Training Processmentioning

confidence: 99%

Process Analysis and Modelling of Operator Performance in Classical and Digitalized Assembly Workstations

Neacşu (Dobrişan),

Niţu,

Gavriluţă

et al. 2024

Processes

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Strong competition in the automotive industry has required manufacturers to implement lean production, both with methods and techniques specific to Industry 4.0. At the same time, universities must provide graduates with specific skills for applying these new production methods and techniques. In this context, a lean learning factory was developed in the Pitesti University Center that allows students to learn about, experiment with, and research new lean manufacturing methods and techniques as well as Industry 4.0 in an environment similar to that of enterprises. The research presented in this study aimed to identify the minimum number of repetitions necessary to train operators to perform the same assembly operation while working at two differently organized workstations: one classic and the other including digital techniques. Several indicators were considered in our analysis, such as the number of errors, the number of stops, the effective duration of the work cycle, and the percentage ratio between the standard duration of cyclical activities and the effective duration of the work cycle. The evolution of these indicators was mathematically modelled by regression functions, using the least squares method. The obtained results also highlight the usefulness of applying the DOJO method as a lean-manufacturing-specific learning technique and the efficiency of implementing digital techniques in work organization.

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Process Analysis and Modelling of Operators Performance in Classical and Digitalized Assembly Workstations

NEACŞU (DOBRIŞAN),

NIŢU,

GAVRILUŢĂ

et al. 2024

Preprint

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The strong competition in the automotive industry has required manufacturers to implement lean production, both with methods and techniques specific to Industry 4.0. At the same time, universities must provide graduates with specific skills for applying these new production methods and techniques. In this context, a Lean Learning Factory was developed in the Pitesti University Center, which allows students to learn, experiment, and research, in an environment similar to that of enterprises, the new Lean Manufacturing methods and techniques, and Industry 4.0. The research presented in this study had as its objective identifying the minimum number of repetitions necessary to train operators who serve two differently organized workstations, one classic, the other including digital techniques, but on which the same assembly operation is performed. Several indicators were considered in the analysis, such as the number of errors, the number of stops, the effective duration of the work cycle, and the percentage ratio between the standard duration of cyclical activities and the effective duration of the work cycle. The evolution of these indicators was mathematically modelled by regression functions, using the least squares method. The obtained results also highlight the usefulness of applying the DOJO method as a Lean manufacturing-specific learning technique and the efficiency of implementing digital techniques in work organization.

show abstract

Methodology for improving production flows on an assembly line

Cited by 3 publications

References 11 publications

Algorithm to Use Some Specific Lean Manufacturing Methods: Application in an Industrial Production Process

Algorithm to Use Some Specific Lean Manufacturing Methods: Application in an Industrial Production Process

Process Analysis and Modelling of Operator Performance in Classical and Digitalized Assembly Workstations

Process Analysis and Modelling of Operators Performance in Classical and Digitalized Assembly Workstations

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