Reducing High Setup Time in Assembly Line: A Case Study of Automotive Manufacturing Company in Malaysia

Esa, Mashitah Mohamed; Rahman, Norazah Abd; Jamaludin, Mohd Ariff

doi:10.1016/j.sbspro.2015.11.086

Cited by 22 publications

(10 citation statements)

References 8 publications

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“…Sustainable Shop Floor Management System and Industry 4.0 Technologies. Implementing an efficient process optimization approach with industry 4.0 technologies for operational control in a complex environment plays a vital role in shop floor management [2,3,11,17,25,32,39,55,69,82]. Industry 4.0 technologies enormously enhance productivity by maximizing operational excellence, workers' contributions, overall equipment effectiveness, and process adaptability [1,3,20,26,30,88,90,92,105].…”

Section: Enhancement Of Industrial Sustainability Of the Developed Me...mentioning

confidence: 99%

“…e integration of lean and innovative approaches is considered efficient by the shop floor management teams because this integration can enhance productivity and financial profitability within limited constraints [2,3,6,20,22,26,39,55,67,74,90,105]. Furthermore, the developed smart shop floor management system helps in the decision-making stage to implement a suitable approach for maximizing productivity with available resources.…”

Section: Potential Contribution Of the Proposed Smart Manufacturing S...mentioning

confidence: 99%

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A Novel Smart Production Management System for the Enhancement of Industrial Sustainability in Industry 4.0

Tripathi¹,

Chattopadhyaya

Mukhopadhyay

et al. 2022

Mathematical Problems in Engineering

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In industry 4.0, shop floor management teams are increasingly focused on developing an unprecedented strategy to avoid financial losses and address the challenges and problems encountered in operations management. In the present scenario, the management teams use various process optimization approaches for operational control, including lean manufacturing, smart manufacturing, the internet of things, and artificial intelligence. The process optimization approach is used to maximize productivity within limited constraints on the shop floor. The present research aims to develop a smart production management system and suggest an efficient process optimization approach to enhancing industrial sustainability by identifying problems and challenges encountered in the complex shop-floor conditions in industry 4.0. The developed production management system has been prepared by classifying the challenges and problems found in the previous research work and organizing brainstorming sessions. The developed management system has been validated by a comprehensive investigation of a case study of an earthmoving machinery manufacturing unit. The analysis showed that the developed system could enhance operation excellence and industrial sustainability in industry 4.0 by optimizing the utilization of resources on the shop floor within limited constraints. The authors of the present article strongly believe that the developed production management system will improve operational excellence and would be beneficial for industry personnel and researchers in controlling operations management in shop floor management of heavy machinery manufacturing, including industry 4.0.

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Section: Enhancement Of Industrial Sustainability Of the Developed Me...mentioning

confidence: 99%

Section: Potential Contribution Of the Proposed Smart Manufacturing S...mentioning

confidence: 99%

A Novel Smart Production Management System for the Enhancement of Industrial Sustainability in Industry 4.0

Tripathi¹,

Chattopadhyaya

Mukhopadhyay

et al. 2022

Mathematical Problems in Engineering

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“…The concept used in time-related lean production is just in time and SMED (Single Minute Exchange Dies) is associated with model change. In various industries, such as the iron industry, the apparel industry, and the telecommunications panel industry (Gavali, Chavan and Dongre, 2016;Mulyana and Hasibuan, 2017;Singla and Pal, 2017;Zerin, Hossain and Zannat, 2019), SMED is widely used to solve rapid transition problems in the production process (Esa, Rahman and Jamaludin, 2015;Jagtap et al, 2015;Filla, 2016;Gavali, Chavan and Dongre, 2016;Arief and Ikatrinasari, 2018;Syafei and Lokadipati, 2018;Agung and Hasbullah, 2019;Talekar et al, 2019). The application of SMED in the clothing industry had been a success in reducing the replacement time of the model between 0.45-12.6 hours (Singla and Pal, 2017), while the replacement time in the apparel industry had reduced by 283.81 minutes (Zerin, Hossain and Zannat, 2019), It can reduce the retooling time by up to 6 minutes in the food industry (Maalouf and Zaduminska, 2019), it can saved setup time by up to 12 minutes in the pharmaceutical industry (Arief and Ikatrinasari, 2018), it can reduce setup time by up to 9 minutes in the copper cable industry (Setyawan, 2019).…”

Section: Literature Reviewmentioning

confidence: 99%

Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing

Setiawan

Hasibuan

2021

QIP Journal

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Purpose: The research aims to design a performance improvement framework for a new model of sports shoes to increase the ramp-up process time. Methodology/Approach: The approach used the problem-solving system of 8 disciplines, Single Minute Exchange Dies, Visual Management, and the Just In Time principle. Findings: By using the methods described above, the research findings will have a positive impact on the company. Model changeover time was reduced from 600 minutes to 102 minutes, and ramp-up time was reduced from 20 days to 2 days. Research Limitation/Implication: The limitation of this study was that only the CK2946 model was still done as a case study. The cost and other inhibiting factors were also not included in the discussion of this rump-up process. Originality/Value of paper: By integrating SMED, Just In Time, visual management, and using 8-Dicipline, the researcher developed a framework for improved performance for ramping up a new model of sports shoes.

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“…We compare in this section our roadmap to other Lean methods. The majority of Lean methods [5], [8], [18], [20]- [22], [24]- [27], [29], [31]- [33], [36], [39] considered that the Lean approach is a set of tools to apply. [19], [37] emphasized on the principles to satisfy.…”

Section: Related Workmentioning

confidence: 99%

Lean Roadmap: A Step by Step Guide for a Process Manager

Tiamaz¹,

Souissi²

2019

IJITEE

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This paper aims to build a generic roadmap for implementing Lean in different domains in order to improve the business processes. The customization of this roadmap makes it possible to adapt the steps to be followed for Lean implementation, the process manager’s requirements and available resources. An application has been developed in order to facilitate the customization of this roadmap. An analysis of methods from a literature review for Lean implementation was conducted in order to identify the steps to be included in the roadmap. A rigorous approach based on set theory, was therefore proposed and followed to build the roadmap. This roadmap is defined as a set of phases associated with principles, and each phase is defined as a set of steps associated with tools. This roadmap shows to the process manager, the objectives to aim for, the Lean principles to satisfy, and the Lean tools to use.

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Reducing High Setup Time in Assembly Line: A Case Study of Automotive Manufacturing Company in Malaysia

Cited by 22 publications

References 8 publications

A Novel Smart Production Management System for the Enhancement of Industrial Sustainability in Industry 4.0

A Novel Smart Production Management System for the Enhancement of Industrial Sustainability in Industry 4.0

Improve Ramp-Up Performance on the Sewing Process in a Sports Shoe Factory Using 8-Disciplines and Lean Manufacturing

Lean Roadmap: A Step by Step Guide for a Process Manager

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