Applying Lean Maintenance to Optimize Manufacturing Processes in the Supply Chain: A Peruvian Print Company Case

High competitiveness forces companies to reduce their costs and optimize their processes throughout their supply chain. One of these supply chain processes is manufacturing, where the objective may be that the machines work at their maximum efficiency and capacity. This research proposes to increase the effectiveness of the printing process by improving the maintenance applying the Lean concepts. The research will serve as a guide for other companies in the printing industry that seek to increase their production based on the effectiveness of their equipment focused on maintenance processes, which is an important component in their supply chain manufacturing

A Strategic Roadmap for the Manufacturing Industry to Implement Industry 4.0

Industry 4.0 (also referred to as digitization of manufacturing) is characterized by cyber physical systems, automation, and data exchange. It is no longer a future trend and is being employed worldwide by manufacturing organizations, to gain benefits of improved performance, reduced inefficiencies, and lower costs, while improving flexibility. However, the implementation of Industry 4.0 enabling technologies is a difficult task and becomes even more challenging without any standardized approach. The barriers include, but are not limited to, lack of knowledge, inability to realistically quantify the return on investment, and lack of a skilled workforce. This study presents a systematic and content-centric literature review of Industry 4.0 enabling technologies, to highlight their impact on the manufacturing industry. It also provides a strategic roadmap for the implementation of Industry 4.0, based on lean six sigma approaches. The basis of the roadmap is the design for six sigma approach for the development of a new process chain, followed by a continuous improvement plan. The reason for choosing lean six sigma is to provide manufacturers with a sense of familiarity, as they have been employing these principles for removing waste and reducing variability. Major reasons for the rejection of Industry 4.0 implementation methodologies by manufactures are fear of the unknown and resistance to change, whereas the use of lean six sigma can mitigate them. The strategic roadmap presented in this paper can offer a holistic view of phases that manufacturers should undertake and the challenges they might face in their journey toward Industry 4.0 transition

Critical Factors for Introducing Lean Product Development to Small and Medium sized Enterprises in Italy

Abstract Small and medium sized enterprises are the backbone of many economies. Especially in Italy SME's play a major role in the economic system. In the last years many lean methods and approaches were introduced successfully also in small and medium sized enterprises. After a successful introduction in manufacturing the lean approach swapped also on other indirect areas such as engineering and product development. Actually in research we can find only few research on the application of Lean in the R&D departments of SME's. The novelty of this paper is to provide a survey based evaluation of applicability, benefits as well as critical factors of Lean in SME product development. In the survey 54 Italian SME's were asked for their opinion. Further, respondents gave a statement on the introduction of emerging Industry 4.0 techniques in product development and how they can influence the effect of Lean in product development. The main results are that numerous Lean methods can be introduced very quickly promising high potential for improvements and that Lean methods combined with Industry 4.0 technologies act like a booster for efficiency optimization in product development

A K-Chart based implementation framework to attain lean & agile manufacturing

[EN] Lean manufacturing has always ensured production optimization by eliminating wastes, and its implementation has helped in improving the operational performance of the organization since it eliminates the bottlenecks from the processes, thus making them efficient. In lean scenarios, the focus is on “waste” elimination, but in agile manufacturing, the focus is on the ability of comprehension of changing market dynamics and the resilience. One of the major factors in the combined implementation of lean and agile approaches is inadequate planning, monitoring and lack of awareness regarding changing market trends, and this can be countered by utilizing the effective tool of K-Chart. Through a systematic literature review, the authors establish the requirement of effective planning and monitoring in the implementation of integrated lean and agile approach, concluding that K-Chart is a handy tool to adopt for their effective implementation. The result provides a new vision of lean implementation through K-Chart, whereas it provides clarity to practitioners by presenting a K-chart based implementation framework for achieving favourable results. Being a literature review the research work can be validated through a case study approach in future through a comparative analysis between various implementation techniques and K-Chart.Zaheer, S.; Amjad, M.; Rafique, M.; Khan, M. (2020). A K-Chart based implementation framework to attain lean & agile manufacturing. International Journal of Production Management and Engineering. 8(2):123-135. https://doi.org/10.4995/ijpme.2020.12935OJS12313582Abdullah, M. K., Mohd Suradi, N., Jamaluddin, N., Mokhtar, A. S., Abu Talib, A., & Zainuddin, M. F. (2006). K-chart: a tool for research planning and monitoring. J. of Quality Management And Analysis, 2(1), 123-130.Abdullah, M. K., Suradi, N. R. M., Jamaluddin, N., Mokhtar, S., Talib, A. R. A., & Zainuddin, M. F. 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Fast changeovers using AIV and a tool platform

Fast changeover is changing from one process or machine to another line, process, or machine to produce different products or services. Lean aims at reducing waste, improving productivity, and eliminating non-value-added activities to the customer. Whilst achieving sustained continual improvement in certain activities and process of an organization. This project focuses on implementing the methodologies used in lean to improve a manufacturing process that has a changeover, and integrate an AIV (Automated Intelligent Vehicle) with a tool platform or top module into the same process. After careful literature review and research, I was able to set up a process in the machining laboratory of ‘UiT Universitet i Norge, Narvik,’ that is of value to a customer. I identified the step with the need of a fast tool change and optimized the entire process using a software called Simul8. After running the simulation for a period of two weeks and doing some analysis for the processes, I achieved an optimal solution that ensures that all bottlenecks and buffers were eliminated. I also conducted a smooth flow of the process, improving productivity, efficiency, and reduction in changeover time

Bus manufacturing: line balancing and optimization

Bus production is a singular industry due to the product variety and customization usually required by clients. Buses are usually conceived based in a chassis where a frame is built, following the safety rules adopted by the sector. The external view can be similar, but some construction aspects and internal view are usually defined by the client, leading to a high customization. Thus, the bus can be manufactured in a common line, but the different configurations usually lead to a complex assembling process that needs to be carefully thought. Moreover, this kind of industry is permanently subjected to huge competitiveness and sustainable evaluation, which implies a rigorous cost planning and production, avoiding budget problems. This work was carried out in a bus manufacturer located in the Porto surroundings, which produces a large number of bus types for airports, tourism, urban or scholar purposes. The factory has three different production lines, being each one allocated to a different kind of bus manufactured. The lines needed an optimization and balancing improvement, thus, this study intended to make a contribution to this purpose.A produção de autocarros é um negócio singular devido à variedade de produtos e personalização requerida pelos clientes. Os autocarros são normalmente concebidos com base num chassis, onde é construída a estrutura, seguindo as normas de segurança usuais no sector. A vista exterior dos autocarros pode ser similar, mas existem alguns aspectos construtivos e o interior, que são normalmente definidos pelo cliente, conduzindo a uma elevada personalização do produto. Assim, os autocarros podem ser fabricados numa mesma linha, mas com configurações diferentes, levando normalmente a um complexo processo de montagem que necessita ser convenientemente pensado. Acresce que este tipo de indústria está permanentemente sujeito a uma elevada competitividade e avaliação da sua sustentabilidade, evitando problemas relacionados com o não cumprimento do orçamento inicial. Este trabalho foi desenvolvido numa empresa construtora de autocarros sediada nos arredores do Porto, a qual produz um diversificado leque de tipos de autocarros para aeroportos, turismo, urbanos ou para transporte escolar. A fábrica possui três linhas diferentes de produção, estando cada uma alocada a um tipo diferente de autocarro fabricado. As linhas de produção necessitavam de uma otimização e balanceamento e este estudo pretendeu dar uma contribuição nesse sentido

Book of abstracts of the ICIEOM-CIO-IIIE International Conference 2015

BOOK OF ABSTRACTS OF THE ICIEOM-CIO-IIIE INTERNATIONAL CONFERENCE 2015: ENGINEERING SYSTEMS AND NETWORKS: The way ahead for industrial engineering and operations managemen

Implementation of Lean Practices in a Higher Education Institution’s Student Affairs Office: A Case Study from a Bosnian University

Higher education is a key element of prosperous communities, and the quality of education should be a priority in attracting prospective students. Good education implies good academic staff, well-equipped laboratories, facilities, and efficient processes. Maintain efficient processes is challenging abut achievable. One of the possible solutions to improve education processes is to pursue a lean strategy in order to reduce waste and non-value-added activities. The purpose of this paper is to combine paying off strategies from manufacturing companies with higher education institutions (HEI), in order to enhance the quality of education and efficiency of higher education institutions. This research deals with application lean tools in university processes with the aim of investigating the possibility of applying lean concepts in HEI. Processes from the student affairs office from a Bosnian university were taken as a case study. The tools were used for data collections, student satisfaction measurement, process efficiency analysis and assessment whether the university is ready for the implementation of the lean concept. As a result, it was observed that communication channels between university and students are weak, the student information system does not respond to students’ needs, internal communication channels need to be improved and human resources are underused. Overall, it was found that the lean strategy can be applied in HEIs but for the successful implementation of lean thinking, lifestyle from top management to lower management must be adopted