Lean manufacturing implementation in a plastic molding industry
Lean manufacturing is a set oftools and methodalogies that aims for the continuous elimination of wastes throughout the production cycle. This research addresses the implementation oflean principles and tools in a small and medium scale industry focusing on the Plastic Injection molding operation...
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| Main Authors: | , |
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| Format: | Conference or Workshop Item |
| Language: | English |
| Published: |
2012
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| Online Access: | http://psasir.upm.edu.my/id/eprint/20828/1/16_20121206113425.pdf http://psasir.upm.edu.my/id/eprint/20828/ |
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| Summary: | Lean manufacturing is a set oftools and methodalogies that aims for the continuous elimination
of wastes throughout the production cycle. This research addresses the implementation oflean
principles and tools in a small and medium scale industry focusing on the Plastic Injection
molding operation. The main target is to plan and test several strategies to eliminate waste on
the shop floor. A systematic approach was used for the implementation of lean principles. This
paper also describes the application of value stream analysis. The present and future states of
value stream maps were constructed to improve the relevant production process by looking for
opportunities to eliminate wastes and its sources and finally to improve the overall process flow.
The implementation of VSM, 5S, SMED, Heijunka, Small lot size, Kanban, milkrun, layout and
process improvement have shown very encouraging results. Productivity has increased to
94.1%, Delivery attainment increased to IOO%, Changeover time was reduced to 38.5 minutes
and reduction in total inventory to 2.86 days. The implementation of lean manufacturing has
proven to be effective and suitable for enabling a continuous improvement process. |
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