Enhancement of Overall Output in a Small Scale Industry through VSM, Line Balancing and Work Standardization

Abstract

In the present scenario, it is necessary to follow lean manufacturing techniques more effectively and efficiently in order to meet the challenges of the global competitive market. Hence it is inevitable to introduce lean techniques which increase the productivity and reduce the lead time that ultimately results in customer satisfaction. Lean manufacturing has widely been executed in large scale industries over the past three decades. Lean means nothing but the creation of more value for customers with fewer resources and is the current trend for management of products and services. Companies are able to respond to changing customer desires with high variety, high quality, and fast throughput times with low cost. Also information management has become much simpler and more accurate. The main aim of this paper is to study the existing system in a small scale automotive component manufacturing industry and use lean tools to reduce lead time without greatly affecting the current working systems in the industry. Standard Operating Procedure (SOP) is used to standardize the production and Kanban is also introduced by indicating the part number and part description to all work stations. Ranked position weight method in line balancing is used to reduce the transportation time of products from one station to another. Cycle time and setup time were reduced by about 350 seconds and 1500 seconds by work standardization and hence the productivity also increased. After implementing SOP the overall lead time reduced from 5780 seconds to 3946 seconds.

Implementation of Total Productive Maintenance to Enhance the Overall Equipment Effectiveness in Medium Scale Industries

“…TPM lean tool seeks to maximize equipment effectiveness throughout the lifetime of the equipment. It strives to maintain the equipment in optimum condition in order to prevent unexpected breakdown, speed losses, and quality defects occurring from process activities [22][23][24][25]. The integration of lean and green practices within parts production in the automotive industry, ultimately achieving an important reduction in production costs [26][27][28][29][30].…”

Implementation of Production Process Standardization—A Case Study of a Publishing Company from the SMEs Sector

“…Some studies report applications of SW to solve problems in production processes. For instance, Nallusamy and Saravanan [28] implemented both line balancing and SW in a small manufacturing company, where it was managed to reduce cycle times to 350 s as it increases productivity. Then, Nallusamy [29] applied the same two tools in the computer numerical control (CNC) industry, where non-value-added (NVA) activities were reduced by 17%, while production significantly increased, from five units a day per two operators to seven units a day per a single operator.…”

Design and Analysis of a Wind Turbine Blade with Dimples to Enhance the Efficiency through CFD with ANSYS R16.0

“…The general public associates' wind turbines with horizontal axis wind turbines and are unaware of the several other technologies based on the vertical axis wind turbines which are less frequently used [5][6][7][8]. The energy absorbed from the wind is converted into mechanical energy by using wind turbines that is used to drive an electrical generator and then converted into electrical energy [9][10][11][12][13]. Based on our requirement airfoil blades are selected from the national renewable energy laboratory Sseries, thicker than the ones that are seen on airplanes and for the generation of about 1.5MW power at wind speeds of 12-20m/s, the optimal blade was found to have a span of 40 meters [14][15][16][17].…”