scholarly journals Kaizen Selection for Continuous Improvement through VSM-Fuzzy-TOPSIS in Small-Scale Enterprises: An Indian Case Study

2018 ◽  
Vol 2018 ◽  
pp. 1-10 ◽  
Author(s):  
Sunil Kumar ◽  
Ashwani Kumar Dhingra ◽  
Bhim Singh
Keyword(s):  
Continuous Improvement ◽  
Cycle Time ◽  
Fuzzy Topsis ◽  
Shop Floor ◽  
Small Scale ◽  
Market Demand ◽  
Current State ◽  
Future State ◽  
Indian Industries

In the era of cut throat competitive market, Indian industries are under tremendous pressure to continuously reduce the cost and improve product quality. The main objective of this research paper is to provide a road map for investigating the opportunities to reduce cost and improve productivity and quality in the existing production system through the application of Lean-Kaizen concept using value stream mapping (VSM) tool at shop floor of an Indian Small-Scale Enterprise (SSE). On the basis of collected data from the selected industry, a current state map was made. After analysis, the current state map was modified to develop a future state map. By comparing current and future state map, the gap areas were identified and takt time (TT) was calculated considering actual market demand. To overcome the gap between current state map and future state map and to synchronize cycle time of each station with talk time, Kaizen event (KE) was proposed. Fuzzy technology for order preference by similarity to ideal solution (TOPSIS) was applied to prioritize and select the appropriate KE for optimized performance level. After analysis of data obtained after application of the Lean-Kaizen concept, the final improvements in terms of improved productivity (57.15%) and reduced lead time (69.47%), reduced cost (65.61%), and station cycle time (75.25%) were recorded. Through the case study drawn from realistic situations of the industry, the authors highlight that implementation of Lean-Kaizen using VSM and fuzzy TOPSIS provides improvement opportunities across the organization. The findings can inspire the SSEs to adopt the Lean-Kaizen concept for optimizing continuous improvement opportunities in their production industry. This study offers the researchers and practitioners a good example for understanding, selecting, and performing KE program. They can even attain more improvement in various areas by establishing or improving these KE programs.

scholarly journals MEMINIMASI PEMBOROSAN DENGAN LEAN MANUFACTURING PADA PROSES PRODUKSI DI PT. IE

2021 ◽  
pp. 1451
Author(s):  
Ahmad Ahmad ◽  
Helena JK ◽  
Andrean Yonathan
Keyword(s):  
Waiting Time ◽  
Cycle Time ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Fault Tree Analysis ◽  
Value Stream Mapping ◽  
Tree Analysis ◽  
Value Stream ◽  
Current State ◽  
Future State

PT. IE is engaged in the business of making Lighting and Lampposts. Based on observations and interviews, there are still some wastes that arise in the flow of the production process, among which there are still many wastes of waiting time, transportation, movement and inventory. These wastes cause the product completion time to be longer and the resulting quality decreases. To eliminate or reduce waste, it is necessary to apply Lean Manufacturing. Lean Manufacturing is a systematic approach to eliminating waste and changing processes by identifying and reducing waste with continuous improvement and striving to create a production flow along the value stream by eliminating all forms of waste and increasing the added value of products to customers. From the Pareto diagram, it is found that transportation waste has the highest percentage of 26.21%, waiting time is 21.38%, motion waste is 19.31% and waste inventories are 15.17%. while the results of the Value Stream Mapping Current State Map mapping obtained a production lead time of 7,680 seconds and a total cycle time of 6,660 seconds and a PCE Current State Map value of 53.09%. Identify the root causes of waste using Fishbone diagrams, 5 Why Analysis, 5W+1H, Fault Tree Analysis and FMEA. After corrective actions have been taken, based on the Value Stream Mapping Future mapping there is a decrease in production lead time to 5,220 seconds and a decrease in total cycle time to 4,860 seconds and an increase in PCE Future State Map to 68.10% so that there is an increase of 15.01% which shows The company's production process has become more Lean.PT. IE bergerak dalam bisnis pembuatan Lighting dan Tiang Lampu. Berdasarkan observasi dan wawancara, masih terdapat beberapa pemborosan (waste) yang timbul di aliran proses produksi di antaranya masih banyak terjadi pemborosan-pemborosan waktu tunggu, transportasi, gerakan dan inventori. Pemborosan-pemborosan tersebut menyebabkan waktu penyelesaian produk menjadi lebih lama dan kualitas yang dihasilkan menurun. Untuk menghilangkan atau mengurangi pemborosan diperlukan adanya penerapan Lean Manufacturing.Lean Manufacturing merupakan pendekatan sistematik untuk mengeliminasi pemborosan dan mengubah proses dengan cara mengidentifikasi dan mengurangi pemborosan dengan perbaikan kontinu dan berupaya untuk menciptakan aliran produksi sepanjang value stream dengan menghilangkan segala bentuk pemborosan serta meningkatkan nilai tambah produk kepada pelanggan. Dari diagram Pareto ditemukan waste transportasi memiliki persentase paling tinggi sebesar 26,21%, waktu tunggu  21,38%, waste motion 19,31% dan waste inventories 15,17%. sedangkan hasil pemetaan Value Stream Mapping Current State Map diperoleh production lead time selama 7.680 detik dan total cycle time selama 6.660 detik serta nilai PCE Current State Map sebesar 53,09%. Identifikasi akar permasalahan pemborosan menggunakan diagram Fishbone, 5 Why Analysis, 5W+1H, Fault Tree Analysis dan FMEA. Setelah dilakukan tindakan–tindakan perbaikan, berdasarkan pemetaan Value Stream Mapping Future ada penurunan production lead time menjadi 5.220 detik dan penurunan total cycle time menjadi 4.860 detik serta ada peningkatan PCE Future State Map menjadi 68,10% sehingga ada peningkatan 15,01% yang menunjukan proses produksi perusahaan telah menjadi lebih Lean.

An application of 5S concept to organize the workplace at a scientific instruments manufacturing company

2015 ◽  
Vol 6 (1) ◽  
pp. 73-88 ◽  
Author(s):  
Shaman Gupta ◽  
Sanjiv Kumar Jain
Keyword(s):  
Design Methodology ◽  
Shop Floor ◽  
Small Scale ◽  
Content Type ◽  
Audit Score ◽  
Manufacturing Organization ◽  
Practical Implications ◽  
Cause And Effect Diagram ◽  
Collection Methods

Purpose – The purpose of this paper is to use the 5S tool to assist a small-scale manufacturing organization to become more productive and more efficient. Design/methodology/approach – A simple approach has been adopted to create the teams for implementing 5S. Cause-and-effect diagram has been studied for shop floor analysis. Later, four data collection methods have been used to ensure right implementation of the 5S. Findings – In the frames of this case study, it has been analyzed that implementation of “5S” resulted in overall improvement of the organization. With the implementation of “5S”, major benefits in the form of tool searching time have been achieved. Tool searching time from shop floor has been reduced from 30 minutes to 5 minutes. “5S” audit has been conducted in the organization. “5S” audit score has been increased from 7 (Week 1) to 55 (Week 20). Practical implications – 5S is a powerful tool and can be implemented in various industries whether micro, small, medium or large. Implementation of 5S has large horizontal development and can be implemented in all the workstations of an organization. Originality/value – The publications and case study presented in this paper will be useful to researchers, professionals and others concerned with this subject to understand the significance of 5S.

scholarly journals Improving Concrete Waste Rate Generation of Structure Projects in Leading Construction Firm in Indonesia

2021 ◽  
Vol 3 (4) ◽  
pp. 12-17
Author(s):  
Daniela Dea Hapsari ◽  
Sumarsono Sudarto ◽  
Gembong Baskoro
Keyword(s):  
Waste Management ◽  
Waste Generation ◽  
Current State ◽  
Future State ◽  
Construction Firm ◽  
Actual Field ◽  
Waste Rate ◽  
Waste Generation Rate ◽  
Management Issues

The Construction and Demolition (C&D) industry is very close to various waste management issues as the generation of waste is inevitable in every construction. In Indonesia, to make an applicable implementation of C&D Waste Management, the improvement must be made by looking into the actual field process. The improvement uses DMAIC as the lean tools and VSM to state the current process of material from its delivery on the site into a waste. Waste that is being monitored is the most used materials in the case study project which are concrete. A notable project was taken for the study as it will help other structure projects to imitate the down-to-earth future state, aiming at the reduction of waste generation rate and also business process improvement. The result shows that the process of concrete from orders to waste took eight steps, and three of them are improved, producing 3% lesser waste from the current state. The best scenario WGR were analyzed to also answer the stakeholder interest within the case study.

scholarly journals Digital Transformation Design towards Logistics 4.0 in SME: A Case Study for PT XYZ

2021 ◽  
Vol 3 (2) ◽  
pp. 395-405
Author(s):  
Krisna Wardhana ◽  
Prio Utomo ◽  
Friska Natalia
Keyword(s):  
Research Method ◽  
Rapid Development ◽  
Digital Transformation ◽  
Maturity Model ◽  
Economic Sector ◽  
Business Growth ◽  
Current State ◽  
Future State ◽  
Information And Communication

The rapid development of technology and information and communication has a direct impact on the business of the Indonesian people. SMEs are one of the pillars in the economic sector in Indonesia. However, logistics has always been an obstacle to business growth in the SME sector. In Indonesia, logistics costs are still high compared to GDP, which is the background of problems that can be solved by implementing logistics 4.0. This literature will provide input for SME entrepreneurs, who will carry out digital transformation in the logistics sector of their business. The inputs that will be given include the importance of digital transformation in the logistics sector and the benefits that will be provided as a result of digital transformation. By using the digital maturity model for logistics 4.0 concept as a research method, an SME will be able to find its current state and also be able to determine strategies that will help SMEs go to their intended future state. Various analyzes will be carried out to determine the state of the SME business, so that appropriate digital transformation can be carried out regarding the SME logistics current state.

scholarly journals Application of value stream mapping to enhance productivity by reducing manufacturing lead time in a manufacturing company: A case study

2021 ◽  
Vol 19 (1) ◽  
pp. 11-22
Author(s):  
Aditya S. Patil ◽  
Mahesh V. Pisal ◽  
Chandrakant T. Suryavanshi
Keyword(s):  
Lead Time ◽  
Value Stream Mapping ◽  
Value Stream ◽  
Lead Time Reduction ◽  
Current State ◽  
Future State ◽  
Short Lead Time ◽  
Time Gap ◽  
Value Stream Map

Lead time is a time gap between initiation and completion of the processes or product. The lead time directly affects productivity. Short lead time results in higher output thus add more value in a given period. Value stream map is an effective tool to describe the overall process from order to delivery. In this study, there is lead time reduction by generation current state and future state for a process using various techniques. Thus, the main aim of this work to enhance production by reduction of lead time. Finally, gain in production, reduction in lead time, and reduction in inventory between the stations are also reported.

scholarly journals Providing a Model For Assessing Risk Management Of Construction Projects With A Sustainable Development Approach: Case Studies Of Small-Scale Power Plants

2020 ◽  
Vol 8 (1) ◽  
pp. 15-27
Author(s):  
Mehrdad Masoudnejad ◽  
Siroos Gholampour ◽  
Morteza Rayati ◽  
Fateme Nikzad
Keyword(s):  
Construction Projects ◽  
Power Plants ◽  
Fuzzy Topsis ◽  
Small Scale ◽  
Analysis Method ◽  
The Social ◽  
Project Risks ◽  
Development Approach ◽  
Project Objectives

Economic growth in developing countries requires the implementation of infrastructural projects such as power plants, the sustainability of which plays an important role in the social, economic, and environmental development. Despite, these projects are always associated with uncertainties and risks due to features such as uniqueness, unspecified time, the need for specific equipment, correlation between different phases and so on. Therefore, in the present study, a small-scale power plants in Mazandaran was subjected to a case study by which the project risks were properly studied. By interviewing the experts associated with the construction of the power plant, 34 risks were identified and subsequently categorized into four categories of environmental, economic, social, and technical. Then, using the failure factor analysis method, their effects were evaluated, and critical risks were identified. In the next step, Fuzzy TOPSIS hierarchical analysis method was used to prioritize critical risks according to the project objectives in accordance with the PMBOK project management standard. After prioritizing the critical risks, in accordance with the real conditions of these projects, suggestions were made to respond and face the critical risks

An application of value stream mapping in auto-ancillary industry: a case study

2019 ◽  
Vol 32 (1) ◽  
pp. 162-182 ◽  
Author(s):  
Naga Vamsi Krishna Jasti ◽  
Srinivas Kota ◽  
Kuldip Singh Sangwan
Keyword(s):  
Product Family ◽  
Value Stream Mapping ◽  
Inventory Level ◽  
Specific Product ◽  
Content Type ◽  
Value Stream ◽  
Current State ◽  
Future State ◽  
Auto Component

Purpose Lean manufacturing (LM) plays a major role in eliminating wastes (activities/resources) in a manufacturing organization. Value stream mapping (VSM) is one of the critical tools in LM which will help in identifying wastes in materials and information flow in a specific product family. The purpose of this paper is to illustrate the significance of VSM in the auto-ancillary industry in enhancing the productivity and the quality. Design/methodology/approach A case study approach is followed to demonstrate the significance of VSM in identifying various wastes in the auto-ancillary industry. The study has been performed by implementing seven critical steps. A product family is identified based on the customer demand and a cross functional team with specialized experts was formed. The overall processes with sequence are mapped using process flowchart. A cross functional team has been formed to develop the current state of VSM and perform a critical analysis to identify shortcomings. An investigation was performed to overcome the existing shortcomings by identifying opportunities. The relevant kaizens to improve the current state have been proposed. The cross functional team of experts have performed a feasibility study on implementation of proposed kaizens. Finally, a future state of VSM after implementation of feasible kaizens has been reported. Findings The results show that future state of VSM brings out the positive impact with respect to process ratio, TAKT time, process inventory level, total lead time and bottleneck time. The proposed improvement also helped to achieve higher customer satisfaction in terms of increased quality, reduced cost and on time delivery. Research limitations/implications Present study is focussed on a single product family cell in one of the auto-component organization. Originality/value Helps practitioners in the auto-component industry to implement the VSM effectively in their organization.

scholarly journals Towards a Standardized Questionnaire for Measuring Agility at Team Level

2021 ◽  
pp. 71-85
Author(s):  
Hanna Looks ◽  
Jannik Fangmann ◽  
Jörg Thomaschewski ◽  
María-José Escalona ◽  
Eva-Maria Schön
Keyword(s):  
Continuous Improvement ◽  
Learning Process ◽  
Continuous Learning ◽  
Self Organized ◽  
Current State ◽  
Six Dimensions ◽  
The Individual ◽  
The Way

AbstractContext: Twenty years after the publication of the agile manifesto, agility is becoming more and more popular in different contexts. Agile values are changing the way people work together and influence people’s mindset as well as the culture of organizations. Many organizations have understood that continuous improvement is based on measurement.Objective: The objective of this paper is to present how agility can be measured at the team level. For this reason, we will introduce our questionnaire for measuring agility, which is based on the agile values of the manifesto.Method: We developed a questionnaire comprising 36 items that measure the current state of a team’s agility in six dimensions (communicative, change-affine, iterative, self-organized, product-driven and improvement-oriented). This questionnaire has been evaluated with respect to several expert reviews and in a case study.Results: The questionnaire provides a method for measuring the current state of agility, which takes the individual context of the team into account. Furthermore, our research shows, that this technique enables the user to uncover dysfunctionalities in a team.Conclusion: Practitioners and organizations can use our questionnaire to optimize collaboration within their teams in terms of agility. In particular, the value delivery of an organization can be increased by optimizing collaboration at the team level. The development of this questionnaire is a continuous learning process with the aim to develop a standardized questionnaire for measuring agility.

scholarly journals Simulation Based Approach for the Industrialization of a Cabinet Manufacturing Facility

2019 ◽  
pp. 301-308
Author(s):  
Ryan Brown ◽  
Chelsea Ritter ◽  
Mohamed Al-Hussein
Keyword(s):  
Lead Time ◽  
Facility Layout ◽  
Movement Analysis ◽  
Production Methods ◽  
Lean Principles ◽  
Current State ◽  
Future State ◽  
Simulation Based ◽  
Current Production

High-end cabinet making is traditionally an artisan process that utilizes few manufacturing principles. Manufacturing lead time, labor hours required, and productivity can be improved by industrializing the process. This paper focuses on a case study of a high-end cabinet manufacturer in Edmonton AB, Canada and the proposed process and facility improvements. First, computer simulation using Simphony.NET and movement analysis of people/materials of the cabinet manufacturer’s current state of operations is conducted to establish a baseline. Next, suggested process and facility layout improvements and their anticipated results are quantified through future state simulation in order to aid management in making decisions for plant changes and to prove their effectiveness. These improvements include: application of lean principles, modification of their current production methods to reduce bottlenecks, and future state facility layout based on an optimized flow of people and materials.

Sign in / Sign up

Export Citation Format

Share Document