Implementation of Lean Manufacturing to Reduce the Delivery Time of a Replacement Part to Dealers: A Case Study

Abstract

In today’s automotive industry, Lean production systems are used successfully to reduce delivery times. The current case study addresses a problem that affects an automotive company, which is the excessive delivery time of a spare part to its both national and international authorized dealers. In order to reduce the delivery time of this replacement part, the Lean Manufacturing methodology was used. For this purpose, the value stream mapping and the proposed A3 report are the tools used. With the use of these tools, activities that did not add any value are eliminated or modified; in addition, the logistical flow of the modules of the door-side trim panel delivery process is improved. As a result, added value is increased, the delivery time is reduced (for Mexico) and the number of product variants is reduced. Now, the painting process is done by the authorized dealers, and the number of pieces used for every spare part was estimated. The study demonstrates that the integration of value stream mapping administrative/productive in conjunction with the A3 report proposal allows to identify and eliminate waste in the delivery process.

Incorporating Variability in Lean Manufacturing: A Fuzzy Value Stream Mapping Approach

“…e core of VSM consists of the definition of a current-state VSM and a future-state VSM [14,15]. A graphical presentation of both materials and information flow in the current system is defined as a current-state VSM, which has a timeline showing the average time spent by an item at each stage of the production process in both value-added and non-value-added activities [16].…”

Lean Facility Management 4.0: A Case Study

“…With the publication of the two books Lean Thinking by Womack and Jones and The Machine that Changed the World by Womack, Jones and Roos, the familiarization of the term "lean" has become very popular in various sectors of activity other than production and manufacturing [24].As long as there is waste, lean can be used, which means that its application is not limited exclusively to manufacturing areas [25].…”

Nagyvállalatok logisztikai dokumentációs folyamatainak feltérképezése

“…A logisztikai folyamatokra, különösen nagyvállalati környezetben, egyre nagyobb hatást gyakorol a lean filozófia. Olyan területeken jelenik meg a lean filozófia különböző mélységű alkalmazása, mint a hagyományos és additív gyártás [10], érinti nem csupán a gyártási folyamatot, hanem az ahhoz kapcsolódó teljes ellátási láncot [11,12] és egyre kiterjedtebb mértékben alkalmazza az Ipar 4.0 technológiákat, különösen a szenzorhálózatokat [13]. Nagyvállalati környezetben az ismert lean eszközök használata mellett [14] a folyamatfejlesztés fontos eszközévé vált a szimuláció [15,16].…”