An Application of Lean Manufacturing Techniques in Paint Manufacturing Company: A Case Study

Abstract

As a result of the recession in Saudi Arabia, the manufacturing companies start thinking to reduce the operational cost and increasing the productivity through lean manufacturing principles. This paper is focused on increasing the productivity of a paint manufacturing company through implementing some of the lean manufacturing techniques. First, Value stream mapping analysis carried on throughout the manufacturing process and the areas of improvements in the company has been identified using fishbone diagram. Second, Work Place Organization (5S), Single Minute Exchange of Dies (SMED), Work Standardization and Kanban are the lean manufacturing techniques selected to solve different problems facing the company in these areas of improvements. A systematic approach of each technique implemented to measure its effect on the company productivity. It is observed that, applying (5S) and (SMED) techniques in the filling process decreased the changeover time by 59% and increased the daily productivity. Pareto chart recommended using work standardization in the charging process led to reduce the defects batches by 57%. Kanban system eliminated the shortages of semi-finish product and increased the output of the pre-weighing batches by 57%. In addition, overtime hours reduced by 77% and waste handling reduced by 85% and 53% for the non-hazardous and hazardous waste respectively