Implementation Of Lean Process Management Through Enhanced Problem Solving Capabilities.

All Original Equipment Manufacturers (OEM) organizations in Aerospace, Automotive and Electronics industries had to upgrade their functions. These organizations including suppliers and solutions providers are duty bound to improve their functions through strategic initiatives. One such initiative is Lean Process Management. Lean Process Management has proven to aid organizations in developing manufacturing and administrative management solutions and make the organization a leaner at the same time a 'fitter' one, achieving World Class standards in terms of production, quality, marketing, etc, etc. The issue or problem is, although a number of authors, experts, researchers have discussed the lean process management as part organization centric issues, they failed to provide an effective lean process management system. Besides the need to formulate an effective lean process as suggested by some authors, another important reason suggested is the employee's development aspect regarding how to unlock the infinite potential of their workforce. This employee's development is basically the problem solving capabilities of the employees while implementing the Lean through clear cutting protocols or processes of Lean Process Management

The roles of communication process for an effective lean manufacturing implementation

Many companies are implementing lean manufacturing concept in order to remain competitive and sustainable, however, not many of them are successful in the process due to various reasons. Communication is an important aspect of lean process in order to successfully implement lean manufacturing. This paper determines the roles of communication process in ensuring a successful implementation of leanness in manufacturing companies. All the information of lean manufacturing practices and roles of communication in the implementation were compiled from related journals, books and websites. A study was conducted in an aerospace manufacturing in Malaysia. A five-point scale questionnaire is used as the study instrument. These questionnaires were distributed to 45 employees working in a kitting department and to 8 top management people. The results indicate that the degree of leanness were moderate

A Framework To Develop Tools & Techniques Requirements Methodology For Implementing Lean Manufacturing

Increased global competition and customer demands that are looking for better quality product with less cost seem to force companies into implementing lean tools and techniques in their production line. This can lead them to keep or strengthen their competitive position by eliminating the waste of non value added activities and producing value to product that meet customer requirements without affecting the actual quality of the product produce. Example can be found in the automotive industry, electronic industry, aerospace industry, but also the service industry. The deployment of tools and techniques of lean manufacturing became important factor in implementing LM in manufacturing industry. This tools and techniques must be deploying properly so it can bring continuous improvement and sustainability in manufacturing perspective. This PhD proposal aspires to research the main question of how to determine the appropriate tools and techniques requirement methodology for an organization to implement and what are the tools and techniques that need to be deployed to achieve successful implementation. The literature review concerning this area of research has established that there were gaps in the knowledge that required further research. These research gaps with research scope are presented in detail in this paper. The overall specifications of the proposed methodology are also discussed

STUDY OF THE OPTIMUM CONDITION TOWARDS THE INDUCING PARAFFIN WAX LDPE

Low Density Polyethelene is a thermoplastic resin extracted from petroleum based, whereas the wax is an oily organic component that is contains of alkanes, ester, polyester, and hydroxyester. The purpose of this research is to find out the optimum conditions of the wax produced by inducing LDPE. The experiment is carried out by mixing the wax and LDPE into four new polymer compositions, in which the higher value of the tensile strength, Young’s modulus, and hardness are obtained by mixing between 90 wt. % LDPE with 10 wt. % wax, rather than compared to pure LDPE. The results are 8.896 MPa, 247.602 MPa and 50.9 respectively. However, only the strength impact that has a lower value as much as 31.38 %. By SEM analysis, the improvement of mechanical properties value examined in which the most suitable of optimal composition is 90 wt. % LDPE with 10 wt. % wax. The LDPE/wax mixture produces a new polymer and alters the properties of pure LDPE

Novel availability and performance ratio for internal transportation and manufacturing processes in job shop company

Purpose: Purpose of this study includes the quantification of the impact of transportation efficiency onto the workstations the transportation serves in term of throughput and total lead time elapsed by product. Besides, it aims to synchronize the capacity available among workstations throughout a production line by studying the upper limit of throughput could be afforded by each workstation as well as their connection with each other. This study is also done on the purpose of promoting fulfillment of customer demand at shorter delivery time and minimal equipment utilization. Investigation on implementation of Overall Equipment Effectiveness (OEE) in an aerospace part-manufacturing company is studied to track out the potential opportunities to be improved. Design/methodology/approach: Site observation is conducted on all the five manufacturing workstations in the aforementioned aerospace part manufacturing company. Time data of both automated processes and manual processes are collected and they are used to construct simulation model. From that, various scenarios of transportation efficiency are simulated in Experiment 1. In addition, Experiment 2 is also set to examine the maximum capacity of each workstation. All of these are to highlight the relationship between workstation and processes and to verify the condition of imbalanced capacity among workstations in the company. In short, this has necessitated the integration of workstation and transportation activities within the company. These are followed by proposal of measures to quantify the wastes identified. Findings: The paper finds that implementation of OEE alone does not consider the reasonability of customer demand fulfillment. The results show that both transportation efficiency and imbalanced capacity throughout production system are not emphasized by OEE implementation in the case company. Therefore, responsibility of all workstations and transportation process in delivering demand on time are quantified. Transportation process which serves as the connectors of manufacturing processes is quantified and monitored by proposed Transportation Measure (TM) whereas workstations are measured using novel availability and performance ratio. Research limitations/implications: Future research should be conducted to examine the impact of other station within a company such as warehouse and logistic department to the performance of equipment and materials in manufacturing workstation. Besides, the material availability as well as the skills or performance of man power could be further incorporated into the measures to consider all the entities involved in manufacturing processes. Practical implications: The proposed availability and performance ratio for both transportation and manufacturing processes, which are related to each other, help in promoting better effectiveness of production system in terms of production amount and lead time. Besides, reasonable utilization equipment and minimal consumption of material are incorporated in the measures to promote Lean way in fulfilling customer demand. The effectiveness of entire production line is examined as a unity with joint responsibility under varying transportation efficiency and cycle time of each workstation. Both measures could be implemented together to optimize the production system and quantify the hidden wastes which are neglected in the OEE implementation. Originality/value: The novel availability and performance ratio are proposed to consider customer demand, historical equipment utilization and Takt time of each workstation to examine the possibility and reasonability of demand fulfillment. This prevents both over-processing and overproduction issues which are invisible in OEE. Furthermore, delay propagation throughout production system and interrelationship between processes are quantified under transportation measure. Other novelty of the paper is that it monitors the waiting time and lead time spent in each workstation at the same time considering utilization of workstation. The proposed Transportation Measure (TM) aims to reduce the queue length and waiting time at destination workstation at minimal utilization of forklift. It also promotes less capacity investment in transportation and prioritizes its scheduling according to urgency of destination workstation.Peer Reviewe

Lean environmental management integration system for sustainability of ISO 14001:2004 standard implementation

Purpose: The purpose of this study is to present a model for integrating Lean Principles with ISO 14001 Environmental Management System. Design/methodology: To achieve the objective of the study, the methodology used in this study is based on preliminary literature review of ISO 14001 standards and Lean Principles as well as certain case reports from various proponents and authors of ISO 14001 and Lean as noted in various articles and journals and some books. Findings: The findings of this study are a new model called Lean Environmental Management Integration System (LEMIS) has been developed and leads to the creation of these measurement standards for evaluating the organization, making its environmental efforts more realistic, focused and attainable.Research limitations/implications: Future research should be conducted case studies in this direction are required to be conducted for examining the feasibility of amalgamation and implementing ISO 14001:2004 standards with the philosophy of Lean Principles to enable the achievement of world class standards. Practical implications: This model helps to eliminate any wasteful processes in the organization’s implementation of the ISO 14001 standard thus leading to higher environmental performance. Integrating the standard with Lean principles through LEMIS model helps to specify these performance measures making the standard achieve sustainability and continual improvement. Originality/value: This study presents a unique approach of integrating the two main models, namely Lean Principles and ISO 14001 Environmental Management System, as a single framework benefiting contemporary organizations.Peer Reviewe

The roles of communication process for an effective lean manufacturing implementation

Many companies are implementing lean manufacturing concept in order to remain competitive and sustainable, however, not many of them are successful in the process due to various reasons. Communication is an important aspect of lean process in order to successfully implement lean manufacturing. This paper determines the roles of communication process in ensuring a successful implementation of leanness in manufacturing companies. All the information of lean manufacturing practices and roles of communication in the implementation were compiled from related journals, books and websites. A study was conducted in an aerospace manufacturing in Malaysia. A five-point scale questionnaire is used as the study instrument. These questionnaires were distributed to 45 employees working in a kitting department and to 8 top management people. The results indicate that the degree of leanness were moderate.Peer Reviewe

Classification Of Losses In Overall Equipment Effectiveness Calculation

The intention of elimination of losses is to improve the efficiency and effectiveness of the production and reduce the unnecessary expenses. OEE is a performance metric of the machine or process and it provides information to the user to monitor and understand the actual situation of the machine compared to the ideal situation of the machine. Although six big losses are defined in the OEE, but it is still not clearly shows the scope of improvements in availability. Most of the time, users are more focus on the breakdown rather than setup process due to breakdown losses have greater impact on the OEE percentage. Therefore, excessive setup time or changeover time is hidden in the OEE. Furthermore, the frequency of the setup process and ideal setup time is not clearly stated in the OEE. The objective of this study is to visualize the availability losses by improve the classification of availability losses. The new classification of losses is examined by real data and it showed better visualization than traditional classification of losses. It is necessary to quantify these losses with modified OEE to visualize the losses in a better way

Model of Transformational Leadership, Risk Management Factors Influencing on Law Performance

The ability of law enforcement organisations to effectively combat crime depends on their use of innovation and workplace transformation. When the need for change in law enforcement organisations' daily operations becomes more and more apparent, transformational leadership has been shown to be extremely beneficial in risk management and enhancing police performance. The right strategy for effective policing development and improving police officer performance is established by this leadership style. The Dubai Police Department's performance in enforcing the law suffers in the absence of effective risk management and transformational leadership, potentially jeopardising the relationship between officers and all departments. As a result, this study created a model outlining the causal links between risk management and transformational leadership and the effectiveness of law enforcement. This study was quantitatively conducted, collecting 381 completed responses that were statistically analysed using SPSS and AMOS. The responses gathered during the data collection process were verified by the reliability analysis. Using fit index parameters to define the relationship between risk management and transformational leadership and law enforcement performance, AMOS analysis revealed that the developed model is satisfactory. The police department will be able to effectively manage risk with the help of this finding in order to reduce crime and create a security plan for the officers