Increasing energy productivity in lean production system with energy oriented value-stream mapping

Rezaeian, Javad; Parviziomran, Irandokht; Mahdavi, Iraj

doi:10.1504/ijpqm.2018.10014455

Cited by 3 publications

(2 citation statements)

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“…19 Best improvement plans derived to evaluate energy productivity in a automobile paint shop production system based on VSM tool. 20 There was a reduction in lead time from 20,550 min to 7069 min, in the total inventory from 1020 to 231 and in WIP from 163 to 27 units in a gear manufacturing company through application of VSM tools that includes kanban, TPM and 5S. 21 Lean-Kaizen concept was applied in a shaft swing arm company using VSM for eliminating waste.…”

Section: Literature Reviewmentioning

confidence: 99%

Reduction of lead time in an automobile rubber components manufacturing process through value stream mapping

Pradeep

Balaji

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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Increasing demand for cost reduction triggers an organisation to focus on optimisation of all the resources and efficiency improvement. Value stream mapping (VSM) finds application in the manufacturing process for achieving this result. VSM is one of the lean manufacturing tools for the identification and reduction of waste in an organisation. This article provides a case study on application of VSM in a automotive rubber parts manufacturing industry where oil seal is produced and supplied to vehicle manufacturers. Purpose of this research is collecting the performance data of the organisation, analyse the gap, apply VSM technique and measure the improved performance. Conceptual framework developed for employees to understand the overall concept and for future researcher to directly apply relevant leans tools for particular problems. As a result of the implementation of VSM, there is a reduction in lead time and waste by increasing the number of cavities from 30 to 36 in curing machine, providing interlock system in curing machine, introducing 3.7 m3 oven, auto trimming machine, magnetic flash separator, auto spring fitting machine, modification of inspection table and packing stacker in the manufacturing process. After implementation there was 81% reduction in lead time, 38% reduction in cycle time, 70% reduction in setup changeover time, 91% reduction in work in process (WIP) inventory and 90% reduction in scrap leading to 69.6% increase in process cycle efficiency by reducing breakdown, setup changeover time and implementing kanban system. Results indicates that implementation of lean tools improves the performance of the organisation.

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Section: Literature Reviewmentioning

confidence: 99%

Reduction of lead time in an automobile rubber components manufacturing process through value stream mapping

Pradeep

Balaji

2022

Proceedings of the Institution of Mechanical Engineers, Part E:

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“…It includes the waste of waiting time, transportation usage, inventory, over-process, over-motion, and defect products (14) (15) (16). Value Stream Mapping (VSM) is one of the lean manufacturing tools or methods that has pictures from all activities (named value added and non-value added) (17) (18). It is needed to carry the products or services to the customers (19).…”

Section: Literature Reviewmentioning

confidence: 99%

Implementation of Lead Time Improvement in the Cutting Production Process using Clustering Data Mining and Lean Manufacturing

Steven

Chin

Nadlifatin

2022

KSS

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In steel companies, there are some processes in the production such as cutting, machining and heat treatment. The production process begins with cutting process and then machining process and the last one is the heat treatment process. It becomes a background that gives the challenge and needs continuous improvement on all aspects, mainly in the cutting process. The research is conducted at one of steel companies located in Pulogadung Industrial Estate. The purpose of the research is to know the factors which cause process lead time cannot be achieved. The methods used are clustering data mining and lean manufacturing. Clustering method can be used to focus on big data and find out clusters or the same pattern. Those clusters are processed with Weka software and using K-means algorithm. Improvement ideas will be implemented to the formed clusters using lean manufacturing such as Single Minute Exchange of Dies (SMED) which have been mapped through value stream mapping, 5S, and Kanban beforehand. The materials’ dimension on the production process is affecting the cutting process lead time. The thicker material diameters will need a longer time to process. With the methods used, lead time of cutting process increased from 3449 minutes to 2165 minutes (3 days to be 2 days). Meanwhile if the “SMED” activities are implemented, the cutting process lead time increased from 187 minutes to 136 minutes. Keywords: Clustering; SMED; Lean Manufacturing; Process Lead Time; Value Stream Mapping

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A literature review of energy waste in the manufacturing industry

Geng

Evans

2022

Computers & Industrial Engineering

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Increasing energy productivity in lean production system with energy oriented value-stream mapping

Cited by 3 publications

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Reduction of lead time in an automobile rubber components manufacturing process through value stream mapping

Reduction of lead time in an automobile rubber components manufacturing process through value stream mapping

Implementation of Lead Time Improvement in the Cutting Production Process using Clustering Data Mining and Lean Manufacturing

A literature review of energy waste in the manufacturing industry

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