Data Analysis in Production Levelling Methodology

Żywicki, Krzysztof; Rewers, Paulina; Bożek, Mariusz

doi:10.1007/978-3-319-56541-5_47

Cited by 11 publications

(5 citation statements)

References 19 publications

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“…A study analyzing the systematic review of many case studies merging lean principles and I4.0 tools found that the majority utilized VSM and simulation due to their function and economic effectiveness (Żywicki et al , 2017).…”

Section: Literature Reviewmentioning

confidence: 99%

“…According to Yilmaz et al (2022), applying combined methods of lean and I4.0 is estimated to reduce costs by 40% within 5-10 years of implementation. The conceptual synergy of I4.0 and lean methods has advanced well-known lean methods, several of which will be illustrated in the following table (Table 1), together with their I4.0 tools: A study analyzing the systematic review of many case studies merging lean principles and I4.0 tools found that the majority utilized VSM and simulation due to their function and economic effectiveness ( _ Zywicki et al, 2017).…”

Section: Literature Reviewmentioning

confidence: 99%

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Improving automated pallet handling procedures at a Saudi milk factory through overall equipment effectiveness

Alnounou

Asiri²,

Alhindi³

et al. 2022

BIJ

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PurposeSaudi Arabia's 2030 vision targets an increase of 34% in non-oil revenue participation in the GDP, thus the need for automation and digital transformation. The Company ER is a market leader producing high-quality dairy products in the Kingdom and is a pioneer in the production industry. The company has recently increased the capacity of its milk factory to meet its vision. An investment was made to automate the pallet handling procedures at the milk factory to provide increased production for daily consumption. The new automation transition in Company ER's milk factory provides a unique opportunity to utilize lean management tools to improve the current automated processes before commercialization.Design/methodology/approachOEE (overall equipment effectiveness) will monitor losses for different operational losses in the new automated system and indicate system improvements, with 85% as the target. Based on DMADV (design, measure, analyze, design and validate) methodology, this study analyzes the entire automated pallet handling system. It uses lean tools to identify areas for improvement, identify waste elements and propose solutions to achieve Company ER's OEE targets.FindingsIn this paper, the outcomes will be presented as documented solutions that address the losses encountered in the production system, showing a 12.8% increase in the system's OEE.Research limitations/implicationsOwing the time and resource constraint, this study only involved automated pallet handling procedures in a milk production facility. Hence, the generalization of the result is slightly limited. More studies in several different processes and sectors are required.Practical implicationsThis study provided a valuable tool for researchers for gaining deeper understanding regarding the lean manufacturing and its implementation. For practitioners, it is useful to evaluate the degree of lean manufacturing tools in their material handling systems.Originality/valueThis study is the first attempt to develop lean manufacturing constructs for evaluating the automated pallet handling procedures in a milk production facility.

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Section: Literature Reviewmentioning

confidence: 99%

Section: Literature Reviewmentioning

confidence: 99%

Improving automated pallet handling procedures at a Saudi milk factory through overall equipment effectiveness

Alnounou

Asiri²,

Alhindi³

et al. 2022

BIJ

View full text Add to dashboard Cite

show abstract

“…In other words, production levelling is a manner of planning, consisting in determining the sequence and the extent of the inflow of products from the production process in such a way that the current demand is satisfied from the warehouse (while maintaining minimum stock of finished goods) and does not result in an unexpected change in the production plan [19][20][21][22].…”

Section: Production Levellingmentioning

confidence: 99%

Management and Production Engineering Review

Rewers¹,

Bożek²,

Kulus³

2019

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The main purpose of this article is to present an author's methodology of production levelling and to show the impact of levelling on the time during which the product passes through the process and on staff performance. The article presents the analysis of literature concerning the method of improving the production process, especially taking production levelling into consideration. The authors focussed on the definition and methodologies of production levelling. A diagram of interrelations showing determinants and efficiency measures of production levelling as well as an author's production levelling methodology have been presented. An example of the implementation of production levelling in one of the departments of a company manufacturing surgical instruments has also been shown. Analysis of the current state, stages of implementation and end effects have been presented. Attention was focussed on the time during which the product passes through the process and on staff performance.

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“…Production leveling (heijunka) is commonly regarded as a method of product sequencing in order to balance production, and increase productivity and flexibility by minimizing differences in workloads [ 6 , 7 ]. According to the authors, production leveling consists of determining the order and size of the batch of manufactured products so that the current demand is met from the warehouse and does not cause sudden changes in the production plan [ 8 – 10 ]. However, production leveling is not applicable to every enterprise and process.…”

Section: Introductionmentioning

confidence: 99%

“…Also, in the case of unit production, in which all components included in the product are unique, leveled production is not possible. It is only possible to implement in the production of standard products, produced in a serial manner, for which the profitable and feasible stations have become a fixed and unchanging production plan [ 10 ].…”

Section: Introductionmentioning

confidence: 99%

A heijunka study for the production of standard parts included in a customized finished product

Rewers

Diakun

2021

PLoS ONE

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Efficient order execution plays a crucial role in the activity of every company. In production planning it is important to find a balance between the fluctuations of orders and stability of production flow regarding the company. One of the methods of achieving this goal is heijunka (production leveling). This paper presents a study of choosing the best variant of the production planning and control system for the production of standard parts. Three variants are investigated regarding delays in order delivery. The analysis of variants was conducted using a simulation method. The method of choosing the best variant for the production system being investigated is also proposed. The results show that the best variant is a mix of production leveling and production "for stock".

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Data Analysis in Production Levelling Methodology

Cited by 11 publications

References 19 publications

Improving automated pallet handling procedures at a Saudi milk factory through overall equipment effectiveness

Improving automated pallet handling procedures at a Saudi milk factory through overall equipment effectiveness

Management and Production Engineering Review

A heijunka study for the production of standard parts included in a customized finished product

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