nach oben

Arabian Journal for Science and Engineering

Erschienen in:

04.12.2019 | Research Article - Systems Engineering

Lean Approach to Enhance Manufacturing Productivity: A Case Study of Saudi Arabian Factory

verfasst von: Ateekh Ur Rehman, Yusuf S. Usmani, Usama Umer, Mohammed Alkahtani

Erschienen in: Arabian Journal for Science and Engineering | Ausgabe 3/2020

Einloggen

Aktivieren Sie unsere intelligente Suche, um passende Fachinhalte oder Patente zu finden.

search-config

KI-gestützte Suche

Aus

Abstract

In a present competitive market, manufacturing industries are compelled to follow a systematic approach to understand and improve manufacturing plant performance. A variety of management tools and philosophies are adopted by different industries to identify areas of opportunity for minimization of waste and maximization of production productivity. Lean manufacturing is a philosophy of waste minimization, productivity enhancement and continuous improvement. This paper considers Saudi Arabian factory as a case study. Accordingly, an approach is presented to measure the manufacturing plant performance and total productivity. Productivity benchmarking is done based on baseline productivity, and manufacturing plant performance index. The detailed case study analysis is done by gathering data from different manufacturing departments. By adopting lean approach, the manufacturing industry was able to improve its performance in each manufacturing departments. After improvement, the whole manufacturing plant performance index improved from 0.77 to 0.86, and the total factor productivity is increased by 11.45%. This case study focuses on resources utilization, man and material movements, production bottlenecks and percentage rejection. Thus, this paper is about the application of lean tools in a company and proposing an approach to apply it in Saudi Arabian factory, and the results can be applied to any other manufacturing company.

Vorheriger Artikel Supply Chain Coordination with Optimal Pricing and Logistics Service Decision in Online Retailing

Nächster Artikel Availability Analysis and Cost Optimization of M/G/1 Fault-Tolerant Machining System with Imperfect Fault Coverage

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Online-Abonnement

Mit Springer Professional "Wirtschaft+Technik" erhalten Sie Zugriff auf:

über 102.000 Bücher
über 537 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Finance + Banking
Management + Führung
Marketing + Vertrieb
Maschinenbau + Werkstoffe
Versicherung + Risiko

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Springer Professional "Technik"

Online-Abonnement

Mit Springer Professional "Technik" erhalten Sie Zugriff auf:

über 67.000 Bücher
über 390 Zeitschriften

aus folgenden Fachgebieten:

Automobil + Motoren
Bauwesen + Immobilien
Business IT + Informatik
Elektrotechnik + Elektronik
Energie + Nachhaltigkeit
Maschinenbau + Werkstoffe

Jetzt Wissensvorsprung sichern!

Jetzt informieren

Pakdil, F.; Leonard, K.M.: Criteria for a lean organisation: development of a lean assessment tool. Int. J. Prod. Res. 52, 4587–4607 (2014). https://doi.org/10.1080/00207543.2013.879614 CrossRef

Azadeh, A.; Zarrin, M.; Abdollahi, M.; Noury, S.; Farahmand, S.: Leanness assessment and optimization by fuzzy cognitive map and multivariate analysis. Expert Syst. Appl. 42, 6050–6064 (2015). https://doi.org/10.1016/j.eswa.2015.04.007 CrossRef

Haq, A.N.; Boddu, V.: An integrated fuzzy QFD and TOPSIS approach to enhance leanness in supply chain. Int. J. Bus. Perform. Supply Chain Model. 7, 171–188 (2015). https://doi.org/10.1504/IJBPSCM.2015.069924 CrossRef

Henao, R.; Sarache, W.; Gómez, I.: Lean manufacturing and sustainable performance: trends and future challenges. J. Clean. Prod. 208, 99–116 (2019). https://doi.org/10.1016/j.jclepro.2018.10.116 CrossRef

Saravanan, V.; Nallusamy, S.; George, A.: Efficiency enhancement in a medium scale gearbox manufacturing company through different lean tools—a case study. https://www.scientific.net/JERA.34.128

Dhiravidamani, P.; Ramkumar, A.S.; Ponnambalam, S.G.; Subramanian, N.: Implementation of lean manufacturing and lean audit system in an auto parts manufacturing industry—an industrial case study. Int. J. Comput. Integr. Manuf. 31, 579–594 (2018). https://doi.org/10.1080/0951192X.2017.1356473 CrossRef

Muñoz-Villamizar, A.; Santos, J.; Garcia-Sabater, J.J.; Lleo, A.; Grau, P.: Green value stream mapping approach to improving productivity and environmental performance. Int. J. Prod. Perform. Manag. (2019). https://doi.org/10.1108/IJPPM-06-2018-0216 CrossRef

Coffey, D.; Thornley, C.: Automation, motivation and lean production reconsidered. Assem. Autom. 26, 98–103 (2006)CrossRef

Biotto, C.; Mota, B.; Araújo, L.; Barbosa, G.; Andrade, F.: Adapted use of andon in a horizontal residential construction project. In: Proceedings of the 22nd Annual Conference of the International Group for Lean Construction: Understanding and Improving Project Based Production, pp. 1295–1305 (2014)

10.

Lam, N.T.; Toi, L.M.; Tuyen, V.T.T.: Lean line balancing for an electronics assembly line. Procedia CIRP 40, 437–442 (2016)CrossRef

11.

Overboom, M.; Small, J.; Naus, F.: Applying lean principles to achieve continuous flow in 3PLs outbound processes. J. Econ. Manag. 11, 65–79 (2013)

12.

Haider, A.; Mirza, J.; Ahmad, W.: Lean capacity planning for tool room: an iterative system improvement approach. Adv. Prod. Eng. Manag. 10, 169–184 (2015)

13.

Imai, M.: Gemba Kaizen: A Commonsense Approach to a Continuous Improvement Strategy. McGraw Hill Professional, New York (2012)

14.

Ward, P.; Zhou, H.: Impact of information technology integration and lean/just-in-time practices on lead-time performance. Decis. Sci. 37, 177–203 (2006)CrossRef

15.

Modarress, B.; Ansari, A.; Lockwood, D.L.: Kaizen costing for lean manufacturing: a case study. Int. J. Prod. Res. 43, 1751–1760 (2005)CrossRef

16.

Ciemnoczolowski, D.D.; Bozer, Y.A.: Performance evaluation of small-batch container delivery systems used in lean manufacturing–Part 2: number of Kanban and workstation starvation. Int. J. Prod. Res. 51, 568–581 (2013)CrossRef

17.

Alaskari, O.; Ahmad, M.M.; Pinedo-Cuenca, R.: Development of a methodology to assist manufacturing SMEs in the selection of appropriate lean tools. Int. J. Lean Six Sigma. 7, 62–84 (2016)CrossRef

18.

Mohamad, E.; Ito, T.; Yuniawan, D.; Ibrahim, M.A.; Saptari, A.; Kasim, M.S.; Izamshah, R.; Shibghatullah, A.S.; Ali, M.M.: A proposal of MUDA indicator agent to estimate lean manufacturing verification. J. Adv. Manuf. Technol. (JAMT) 8, 71–82 (2014)

19.

Jauregui Becker, J.M.; Borst, J.; van der Veen, A.: Improving the overall equipment effectiveness in high-mix-low-volume manufacturing environments. CIRP Ann. 64, 419–422 (2015). https://doi.org/10.1016/j.cirp.2015.04.126 CrossRef

20.

Saurin, T.A.; Ribeiro, J.L.D.; Vidor, G.: A framework for assessing poka-yoke devices. J. Manuf. Syst. 31, 358–366 (2012). https://doi.org/10.1016/j.jmsy.2012.04.001 CrossRef

21.

Cakmakci, M.: Process improvement: performance analysis of the setup time reduction-SMED in the automobile industry. Int. J. Adv. Manuf. Technol. 41, 168–179 (2009). https://doi.org/10.1007/s00170-008-1434-4 CrossRef

22.

Drohomeretski, E.; da Costa, S.E.G.; de Lima, E.P.; Garbuio, P.A.D.R.: Lean, Six Sigma and Lean Six Sigma: an analysis based on operations strategy. Int. J. Prod. Res. 52, 804–824 (2014). https://doi.org/10.1080/00207543.2013.842015 CrossRef

23.

Robinson, S.; Radnor, Z.J.; Burgess, N.; Worthington, C.: SimLean: utilising simulation in the implementation of lean in healthcare. Eur. J. Oper. Res. 219, 188–197 (2012). https://doi.org/10.1016/j.ejor.2011.12.029 CrossRefMATH

24.

Ahuja, I.P.S.; Khamba, J.S.: Total productive maintenance: literature review and directions. Int. J. Qual. Reliab. Manag. 25, 709–756 (2008). https://doi.org/10.1108/02656710810890890 CrossRef

25.

Abdulmalek, F.A.; Rajgopal, J.: Analyzing the benefits of lean manufacturing and value stream mapping via simulation: a process sector case study. Int. J. Prod. Econ. 107, 223–236 (2007). https://doi.org/10.1016/j.ijpe.2006.09.009 CrossRef

26.

Gapp, R.; Fisher, R.; Kobayashi, K.: Implementing 5S within a Japanese context: an integrated management system. Manag. Decis. 46, 565–579 (2008). https://doi.org/10.1108/00251740810865067 CrossRef

27.

Taj, S.: Lean manufacturing performance in China: assessment of 65 manufacturing plants. J. Manuf. Technol. Manag. 19, 217–234 (2008). https://doi.org/10.1108/17410380810847927 CrossRef

28.

Ferdousi, F.: An investigation of manufacturing performance improvement through lean production: a study on Bangladeshi garment firms. Int. J. Bus. Manag. 4, 106 (2009). https://doi.org/10.5539/ijbm.v4n9p106 CrossRef

29.

Singh, B.; Garg, S.K.; Sharma, S.K.; Grewal, C.: Lean implementation and its benefits to production industry. Int. J. Lean Six Sigma 1, 157–168 (2010). https://doi.org/10.1108/20401461011049520 CrossRef

30.

Vinodh, S.; Arvind, K.R.; Somanaathan, M.: Application of value stream mapping in an Indian camshaft manufacturing organisation. J. Manuf. Technol. Manag. 21, 888–900 (2010). https://doi.org/10.1108/17410381011077973 CrossRef

31.

Singh, G.; Belokar, R.M.: Lean manufacturing implementation in the assembly shop of tractor manufacturing company. Int. J. Innov. Technol. and Explor. Eng. 1, 71–74 (2012)

32.

Hemanand, K.; Amuthuselvan, D.: Improving productivity of manufacturing division using lean concepts and development of material gravity feeder–a case study. Int. J. Lean Think. 3, 117–134 (2012)

33.

Rohani, J.M.; Zahraee, S.M.: Production line analysis via value stream mapping: a lean manufacturing process of color industry. Procedia Manuf. 2, 6–10 (2015). https://doi.org/10.1016/j.promfg.2015.07.002 CrossRef

34.

Singh, B.; Garg, S.K.; Sharma, S.K.; Grewal, C.: Lean implementation and its benefits to production industry. Lean Six Sigma J. 1, 157–168 (2010). https://doi.org/10.1108/20401461011049520 CrossRef

35.

Chen, J.C.; Cheng, C.-H.; Huang, P.B.: Supply chain management with lean production and RFID application: a case study. Expert Syst. Appl. 40, 3389–3397 (2013). https://doi.org/10.1016/j.eswa.2012.12.047 CrossRef

36.

Hicks, C.; McGovern, T.; Prior, G.; Smith, I.: Applying lean principles to the design of healthcare facilities. Int. J. Prod. Econ. 170, 677–686 (2015). https://doi.org/10.1016/j.ijpe.2015.05.029 CrossRef

37.

Saraswat, P.; Sain, M.K.; Kumar, D.: Reduction of Work in Process Inventory and Production Lead Time in a Bearing Industry Using Value Stream Mapping Tool. AIRCC Publication (2015)

38.

Choomlucksana, J.; Ongsaranakorn, M.; Suksabai, P.: Improving the productivity of sheet metal stamping subassembly area using the application of lean manufacturing principles. Procedia Manuf. 2, 102–107 (2015). https://doi.org/10.1016/j.promfg.2015.07.090 CrossRef

39.

Bortolotti, T.; Romano, P.; Martínez-Jurado, P.J.; Moyano-Fuentes, J.: Towards a theory for lean implementation in supply networks. Int. J. Prod. Econ. 175, 182–196 (2016). https://doi.org/10.1016/j.ijpe.2016.02.020 CrossRef

40.

Deldar, R.; Soleimani, T.; Harmon, C.; Stevens, L.H.; Sood, R.; Tholpady, S.S.; Chu, M.W.: Improving first case start times using Lean in an academic medical center. Am. J. Surg. 213, 991–995 (2017). https://doi.org/10.1016/j.amjsurg.2016.08.025 CrossRef

41.

Chan, C.O.; Tay, H.L.: Combining lean tools application in kaizen: a field study on the printing industry. Int. J. Prod. Perform. Manag. 67, 45–65 (2017). https://doi.org/10.1108/IJPPM-09-2016-0197 CrossRef

42.

Mahendran, S.; Senthilkumar, A.; Jeyapaul, R.: Analysis of lean manufacturing in an automobile industry - a case study. Int. J. Enterp. Netw. Manag. 9, 129–142 (2018). https://doi.org/10.1504/IJENM.2018.093708 CrossRef

43.

Dave, Y.; Sohani, N.: Improving productivity through lean practices in central India-based manufacturing industries. Lean Six Sigma J. (2019). https://doi.org/10.1108/IJLSS-10-2017-0115 CrossRef

44.

Silva, C.D.C.M.; Arouche, M.N.M.; Lima, Z.M.; Vieira, A.C.S.; Pinheiro, E.M.: Application of lean manufacturing tools: a case study in a mattress factory. J. Lean Syst. 4, 89–106 (2019)

45.

Thomas, H.R.; Maloney, W.F.; Horner, R.M.W.; Smith, G.R.; Handa, V.K.; Sanders, S.R.: Modeling construction labor productivity. J. Constr. Eng. Manag. 116, 705–726 (1990). https://doi.org/10.1061/(ASCE)0733-9364(1990)116:4(705) CrossRef

46.

Rehman, A.U.; Alkhatani, M.; Umer, U.: Multi criteria approach to measure leanness of a manufacturing organization. IEEE Access 6, 20987–20994 (2018). https://doi.org/10.1109/ACCESS.2018.2825344 CrossRef

47.

Thomas, H.R.; Završki, I.: Construction baseline productivity: theory and practice. J. Constr. Eng. Manag. 125, 295–303 (1999). https://doi.org/10.1061/(ASCE)0733-9364(1999)125:5(295) CrossRef

48.

Harris, R.; Harris, C.; Wilson, E.; Womack, J.; Jones, D.; Shook, J.; Ferro, J.: Making materials flow: a lean material-handling guide for operations, production-control, and engineering professionals. Lean Enterprises Inst Inc, Brookline (2003)

Titel: Lean Approach to Enhance Manufacturing Productivity: A Case Study of Saudi Arabian Factory
verfasst von: Ateekh Ur Rehman
Yusuf S. Usmani
Usama Umer
Mohammed Alkahtani
Publikationsdatum: 04.12.2019
Verlag: Springer Berlin Heidelberg
Erschienen in: Arabian Journal for Science and Engineering / Ausgabe 3/2020
Print ISSN: 2193-567X
Elektronische ISSN: 2191-4281
DOI: https://doi.org/10.1007/s13369-019-04277-9

Premium Partner

Marktübersichten

Die im Laufe eines Jahres in der „adhäsion“ veröffentlichten Marktübersichten helfen Anwendern verschiedenster Branchen, sich einen gezielten Überblick über Lieferantenangebote zu verschaffen.

Zur Marktübersicht

Springer Professional

Abstract

Bitte loggen Sie sich ein, um Zugang zu Ihrer Lizenz zu erhalten.

Sie haben noch keine Lizenz? Dann Informieren Sie sich jetzt über unsere Produkte:

Springer Professional "Wirtschaft+Technik"

Springer Professional "Technik"

Weitere Artikel der Ausgabe 3/2020

Modified Whale Optimization Algorithm for Infinitive Impulse Response System Identification

Supply Chain Coordination with Optimal Pricing and Logistics Service Decision in Online Retailing

Optimal Coordination of Overcurrent Relays Using Improved Leadership-Based Grey Wolf Optimizer

Runner-Root Algorithm to Control Sidelobe Level and Null Depths in Linear Antenna Arrays

Prospect Theory-Based Consistency Recovery Strategies with Multiplicative Probabilistic Linguistic Preference Relations in Managing Group Decision Making

Electricity Day-Ahead Market Price Forecasting by Using Artificial Neural Networks: An Application for Turkey

Premium Partner

Marktübersichten