Lead Time Reduction through Execution of Lean Tool for Productivity Enhancement in Small Scale Industries

Abstract

In the current dynamic global market place, especially among small and medium scale manufacturing industries the competition is show rigorous for a profitable survival. To be competent the industries have to necessarily work in an efficient way by updating and implementing new techniques. These day’s manufacturers may have to introduce and prove the success of the products not only faster but also to deliver it to the end users at the right time. The aim of this study has been to present a lean approach in the manufacturing system of injection moulding facility by reducing the change over time. In this research a lean tool of Single Minute Exchange of Die (SMED) has proved to be an effective tool for eliminating waste of time. In SMED the time taken for mould or die exchange should be less than 10 minutes. This improves the productivity by reducing the down time of a machine. The main objective has been to reduce the change over time from the current setup time of 39.94 minutes to less than 10 minutes. After implementing the SMED, the total change over time was reduced by about 67.72% which indirectly reduced production losses and increased the productivity.

Quality and lean practices synergies

“…For example, Cakmakci (2009) found that setup time reduction positively impacts the operational performance and is suitable practice not only for manufacturing improvement but also for equipment design development. Saravanan et al (2018) results indicate the setuptime reduction improves productivity by reducing the equipment downtime.…”

“…Amongst these factors, six of them were related to standardisation, streamlining, operational time, process design, waste and efficiency. These factors are the focus of common practices associated with lean manufacturing, such as setup time reduction (Saravanan et al, 2018;Curado, 2019), process redesign (Al-Salim and Choobineh, 2009;Keil et al, 2011;Bergenwall et al, 2012), cellular manufacturing (Angra et al, 2008;Safaei et al, 2010), throughput time reduction (Muthiah et al, 2008, Van Der Heijden et al, 2012 and factory automation (Muthiah et al, 2008;Figueiredo and Martins, 2010).…”

TISM for analysis of barriers affecting the adoption of lean concepts to electronics component manufacture

“…Frequency of occurrence in literature for quality, etc., and hence fails in achieving the common objective, which is the end user satisfaction. Especially electronics organizations should form collaborative partnerships with suppliers and share market demand information, which would help these firms to tackle bullwhip effect, as this electronics industry involves several supply chain entities from retailer through manufacturer EB 22 No measure for reducing set up time (Lee and Ebrahimpour, 1984;Dora et al, 2014;Saravanan et al, 2018) The organization does not take care of improving setup time, though set up time is found to directly influence product lead time, customer responsiveness and amount of work in process inventory, thereby affecting smooth operation and incurring high carrying costs 3 EB 23 Lack of cohesive research and development road map (Antony et al, 2016;Devi et al, 2013) The organization lacks expertise in innovative activities like development of new products and processes and effectively improving existing products in response to customer feedback 2 EB 24 Changing governmental policies (Devi et al, 2013) The organization does not adapt itself to the changes in economic policies and market regulations of the government from time to time, which will affect competitiveness and profitability of the organization 1 Table I.…”

Lean Tools Applied in Transport and Logistics Services

“…Running small Lean projects in transport and logistic services (Garza-Reyes et al, 2016;Kawa et al, 2019) can induce major improvements in quality (Kuvvetli and Firuzan, 2019), reducing cost of operations and reducing lead time (SARAVANAN et al, 2018). Lean tools help to face the dilemma of improving quality, reducing cost and lead time, meeting the customer demands and providing high quality services (NAINAAR and MASSON, 2018;PONTE et al, 2018).…”