The Study of Lean Layout in an Automotive Parts Manufacturer

Abstract

The term “Lean” was the Japanese model and had been associated with the practice of interpreting the value added activities from those that are wasted (“muda” in Japanese) in an organization and its supply chain [1]. Apart from that, lean was also known as the focus on reducing the non value added (NVA) waste which impedes the flow of the product as it is being transformed in the value chain [2]. Lean manufacturing also means producing only to direct customer orders, creating the need for less on-hand inventory [3]. Lean layout is one of the lean manufacturing tools which have been applied in this automotive parts manufacturer. This tool encourages good visibility and management of the manufacturing system [2]. The U-shape design is incorporated in this case study in order to improve the efficiency of production. In this research, the current production layout is studied and the improvements are conducted by using U-shaped layout which replaced the traditional layout (straight line layout). The results are shown through the figures of the new layout design in the production line.

Serious game for lean layout planning: a proposal for involving company staff within the design process

“…It is a multidimensional approach pioneered by Taiichi Ohno (Toyota's chief engineer), through which the operations and processes constituting a production system are divided into three kinds of activities: non-value-added activities, value-added activities and wastes. The goal is to minimise waste and non-value activities, so as to eliminate everything the customer is not willing to pay for Karlsson and Ahlström (1996) and Salleh and Zain (2012). According to the classification proposed by Ohno (1988), waste in a manufacturing company can be traced back to seven categories: waiting, overproduction, rework, motion, processing, inventory and transportation.…”

“…Such principles (listed in Table 1) correspond to the application of the 5s rules in the case of layout planning (Gupta and Chandna, 2020). The lean layout planning system seeks the elimination of wasteful space and the creation of a layout with minimal risk to business opportunities and possible future changes (Salleh and Zain, 2012). Some successful applications of lean layout planning are shown in the literature concerning different domains including the healthcare sector, fashion industries, and the automotive sector.…”

Application of lean manufacturing concept for redesigning facilities layout in Indonesian home-food industry

“…The focus of lean manufacturing approach is on reducing the NVA waste that impedes the flow of the product as it is being transformed in the value chain (Salleh and Zain, 2011). According to Liker (2004), waste on the shop floor is defined as everything that does not provide added value and disrupt the production processes.…”

“…There are also many previous researches incorporating lean applications to design layout in industry (Heinavaara, 2010; Salleh and Zain, 2011; Mejia and Ramirez, 2012; Sa’udah et al , 2015; Low et al , 2015; Tarigan et al , 2018). Salleh and Zain (2011) adopted lean manufacturing approaches in an automotive parts manufacturer in order to remain competitive in an increasingly global market. They selected APM Plastic Ltd for case study to implement lean layout in molding roof drip production line.…”

Experience in Implementing Lean Technologies in the Field of Transport

“…Many of them are moving towards the creation and integrated development of production systems. If you don't go into the name -and there are quite a few terms for defining lean production [1]: "kaizen", "lin", "Toyota" production system -it is important to understand that it is applicable to any enterprises: by type of production process, size and industry. In order to realize all the advantages of this method, the organization must mature.…”