Application of Kaizen Lean approach to reduce rejections and failure cost at Shop floor of a wire harness manufacturing company

116-123Kaizen is a basic tool of lean manufacturing which is useful for better improvement and cost effectiveness in different organizations. This study describes a sequential method that uses kaizen continuous improvement approach to eliminate the lock release problem of band harness in a Wire Harness Manufacturing unit. Due to releasing of this self-locking type tie band, wire harness was not holding properly against the bracket and wires were not properly tightened which results in high rejection level of the product. Further, it also affects overall quality rating and increasing the rework cost significantly. In present study four problems which are responsible for rejections, are identified through brainstorming. Pareto analysis and rating method are used to know the major problem, responsible for highest rejections and why-why analysis is used to find out the root cause of the identified problem. To eliminate this cause, step by step procedure based on lean manufacturing approach, is applied in the case company. Statistical quality control tools are also used to analyze the problem. This study results in total cost saving of 535.20 $ per annum and beyond this some other tangible or intangible benefits were also observed

Critical success factors of lean manufacturing for Indian ceramic industries: Modelling through interpretive ranking process

271-281In India, majority of manufacturing organizations comes under small and medium size enterprises (SMEs) that are recognized as backbone for the economy by contributing a significant amount in gross domestic product (GDP). In the competitive business environment, SMEs are trying to enhance the value of their production and services on decimating the non-productive activities from their manufacturing systems. It has been reported in previous explorations that lean manufacturing (LM) is an approach to recognize and eliminate different forms of waste from the production process, and improve the business performance. Therefore, SMEs has to follow lean manufacturing to ensure sustainable profitability. To optimise the LM implementation benefits, organization/s must see the different success factors thoroughly. So far, critical success factors (CSFs) of lean manufacturing in labour intensive SMEs were not explored systematically. In this study, CSFs for implementing lean are extracted from literature and were analysedand validated after discussion held with relevant industrial experts/academicians. Interpretive ranking process (IRP) technique was employed to observe the relationship amongst the CSFs. To check the interpretations and pair-wise comparison, a dominance system graph for each performance measures was developed. The results revealed that regular training and education for workers, proper selection of lean tools/techniques and low scrap/rework/elimination of waste are the most CSFs for implementing lean in Indian ceramic SME sector

Modeling and analysis of surface roughness in fused deposition modeling based on infill patterns

92-99This paper presents an approach of modeling for surface roughness of Polylactic Acid (PLA) polymer components printed with Fused Deposition Modeling (FDM) based Additive Manufacturing (AM) process. With additive manufacturing technology one can build the components of metal, polymers and variety of composites with good dimensional accuracy. FDM is one of the additive manufacturing process which is used to build products of various polymers. In this investigation PLA components are built using FDM with different Infill Patterns viz. Zigzag, Triangles and Gyroid. Based on surface roughness measurement of components, predictive mathematical models for surface roughness are generated for different infill patterns. The analysis of surface roughness based on layer thickness and infill pattern is presented. The error between predictive surface roughness and experimental surface roughness ranges between 0.1 to 9.5%. For this investigation Gyroid infill pattern shows favourable results for surface roughness. The workable ranges for process parameter under investigation are infill percentage of 70 to 90 %, layer thickness of 0.2 to 0.22 mm and printing speed of 70 to 90 mm/s

Application of Kaizen Lean approach to Reduce Rejections and Failure Cost at Shop Floor of a Wire Harness Manufacturing Company

Kaizen is basic tool of lean manufacturing which is useful for better improvement and cost effectiveness in different organizations. This study describes a sequential method that uses kaizen continuous improvement approach to eliminate the lock release problem of band harness in a wire harness manufacturing unit. Due to releasing of this self-locking type tie band, wire harness was not holding properly against the bracket and wires were not properly tightened which results high rejection level of the product and further affecting overall quality rating and excessive rework cost was increasing. In present study four problems which are responsible for rejections, are identified through brainstorming. Pareto analysis and rating method are used to know the major problem responsible for highest rejections and why-why analysis is used to find out the root cause of the identified problem. To eliminate this cause, step by step procedure based on lean manufacturing approach, is applied in the case company. Statistical quality control tools are also used to analyze the problem. This study results in total cost saving of 535.20 $ per annum and beyond this some other tangible or intangible benefits were also observed

Critical success factors of lean manufacturing for Indian ceramic industries: Modelling through interpretive ranking process

In India, majority of manufacturing organizations comes under small and medium size enterprises (SMEs) that are recognized as backbone for the economy by contributing a significant amount in gross domestic product (GDP). In the competitive business environment, SMEs are trying to enhance the value of their production and services on decimating the non-productive activities from their manufacturing systems. It has been reported in previous explorations that lean manufacturing (LM) is an approach to recognize and eliminate different forms of waste from the production process, and improve the business performance. Therefore, SMEs has to follow lean manufacturing to ensure sustainable profitability. To optimise the LM implementation benefits, organization/s must see the different success factors thoroughly. So far, critical success factors (CSFs) of lean manufacturing in labour intensive SMEs were not explored systematically. In this study, CSFs for implementing lean are extracted from literature and were analysedand validated after discussion held with relevant industrial experts/academicians. Interpretive ranking process (IRP) technique was employed to observe the relationship amongst the CSFs. To check the interpretations and pair-wise comparison, a dominance system graph for each performance measures was developed. The results revealed that regular training and education for workers, proper selection of lean tools/techniques and low scrap/rework/elimination of waste are the most CSFs for implementing lean in Indian ceramic SME sector

Modelling and Analysis of Surface Roughness in Fused Deposition Modeling Based on Infill Patterns

This paper presents an approach of modeling of surface roughness of Polylactic Acid (PLA) polymer components printed with Fused Deposition Modeling (FDM) based Additive Manufacturing (AM) process. With additive manufacturing technology one can build the components of metal, polymers and variety of composites with good dimensional accuracy. FDM is one of the additive manufacturing process which is used to build products of various polymers. In this investigation PLA components are built using FDM with different Infill Patterns viz. Zigzag, Triangles and Gyroid. Based on surface roughness measurement of components, predictive mathematical models for surface roughness are generated for different infill patterns. The analysis of surface roughness based on layer thickness and infill pattern is presented. The error between predictive surface roughness and experimental surface roughness ranges between 0.1 to 9.5%. For this investigation Gyroid infill pattern shows favourable results for surface roughness. The workable ranges for process parameter under investigation are infill percentage of 70 to 90 %, layer thickness of 0.2 to 0.22 mm and printing speed of 70 to 90 mm/s