Internal Logistics Process Improvement using PDCA: A Case Study in the Automotive Sector

Abstract

Background: The Plan-do-check-act (PDCA) cycle methodology for a continuous improvement project implementation aims for the internal logistics upgrade, which is especially important in the industrial context of a component manufacturing company for the automotive sector. Objectives: The goal is to quantify the gains from waste reduction based on the usage of the PDCA cycle as a tool in the implementation and optimisation of a milk run in an assembly line of a company in the automotive sector by determining the optimal cycle time of supply and the standardisation of the logistic supply process and the materials’ flow. Methods/Approach: The research was conducted through observation and data collection in loco, involving two main phases: planning and implementation. According to the phases of the PDCA cycle, the process was analysed, and tools such as the SIPOC matrix, process stratification, 5S, and visual management were implemented. Results: Using Lean tools, it was possible to reduce waste by establishing concise flows and defining a supply pattern, which resulted in a reduction of movements. The transportation waste was reduced by fixing the position of more than half of the materials in the logistic trailers. The developed Excel simulator provided the logistic train’s optimal cycle time. Conclusions: The assembly line supplied by milk-run was fundamental to highlight a range of improvements in the process of internal supply, such as better integration of stock management systems, greater application of quality, or the adoption of better communication systems between the different areas and employees.

Information Security and Risk Control Model Based on Plan-Do-Check-Action for Digital Libraries

“…According to the PDCA cycle stage, the process is analyzed. This circular management system can integrate inventory management systems and improve quality management [9]. Antoaneta et al proposed a food safety management model based on the PDCA cycle.…”

“…PSO is one of the most popular metaheuristic algorithms, derived from simulating the evolution of bird flight and foraging processes [21]. In the standard PSO process, the speed of each particle is shown in formula (9).…”

Analisis paket damage dan perbaikan kualitas produk pada jasa logistik menggunakan metode PDCA Dan FMEA (Studi Kasus: PT Ninja Xpress)

“…Beberapa pendekatan telah diusulkan oleh penelitian sebelumnya. Peningkatan proses logistik internal menggunakan PDCA: studi kasus di sektor otomotif [8]. Hasil penelitian ini menunjukkan bahwa dengan menggunakan alat Lean, pemborosan dapat dikurangi dengan membuat aliran ringkas dan menentukan pola pasokan, yang menghasilkan pengurangan pergerakan.…”

Urban Waste: Visualizing the Academic Literature through Bibliometric Analysis and Systematic Review

“…What lines of interest could be addressed in the future? The issue of solid waste management is considered highly relevant today, since it is applicable in numerous sectors of economic activity, such as the automotive industry [12], hospitality industry [13], construction [14], agriculture [15], or intelligent manufacturing [16], among others. In addition, and according to the literature review, it is highlighted that several authors have worked on different articles using the bibliometric analysis methodology in the field of urban solid waste (USW) (see, for example [5,6,[17][18][19], among others).…”