The value flow mapping technique will be used to determine what step in production is needed. Subsequently, the part to be improved will contribute to the development of production using the line balancing technique. In Section 2, some articles about lean manufacturing and value stream mapping are researched. Then, literature review is performed and the lean management and manufacturing and also its tool 's importance are explained for companies. In the third section of the project, the short and briefly information of the company and the problem definition about the factory 's
Abstract:- This case study is about 6 sigma manufacturing process by which continuous improvement of the product is done. Mainly the 6 sigma is about improving the quality, In order to identify defects or errors. By using 6 sigma 99.9% the defect will not be there in the product. 6 sigma uses quality management and structural methods. The customer satisfaction can be increased by using this, production cycle can be reduced, reduction of waste and reducing the cost of the project.
This type of help can take the form of a vendor managed inventory (VMI). The TOC distribution link simply extends its buffer sizing and management techniques to its customers’ inventories. Doing so has the effect of smoothing the demand from the customer and reducing order sizes per SKU. VMI results in better availability and inventory turns for both supplier and customer. More than that, the benefits to the non-TOC customers are sufficient to meet the purpose of capitalizing on the decisive competitive edge by giving the customer a powerful reason to be more loyal and give more business to the upstream link.
Production planning and control functions of JIT and TOC system helped Adamas to reduce wastage, work on the bottlenecks to improve the overall profits. In this chapter 1.2, let us discuss about the production planning and control functions and their role in the production processes. 1.2.1 Production Planning Production planning answers the questions related to production such as what to, how much and when to produce. In the words of Jay wild, “Production planning is concerned with the determination, acquisition and arrangement of all facilities necessary for future operations.” Major purpose of production planning is utilising the available resources in an efficient
Taguchi’s robust design method: Taguchi’s methods are used for product quality improvement. Earlier methods relating to quality assurance of a product depended on inspection of the products as and when they rolled out of the production process and those products which did not meet the product specifications or standards were rejected. As per Taguchi, product quality cannot be determined upon inspection alone rather quality has to be embedded as a design into the product right from the production process. Robust design is a product improvement engineering technique in research and development phase so that high quality products can be produced quickly and at a low cost. The concept behind robust design is quality improvement of a product, minimizing the natural variations, without eliminating the common causes.
Lean manufacturing is approached as a cost reduction mechanism. Lean is the pursuit of perfection via a systematic approach to identify and minimize waste through continuous improvement of the value stream; enabling the product or information to flow based on a value determined by the customer. Lean thinking targets to eliminate activities that do not add value (NAV) and increase activities that add value (AV); modify the work flow that are not balanced and orchestrate work overload for the team members and the processes as well. Shigeo Shingo expert in manufacturing illustrated that the most dangerous kind of wastes is the waste we do not recognize. For that truth waste should be eradicated by term of value-based planning to avoid any out
The assignable causes of variability can be detected and eliminated that would reduce the overall variability. As a result of eliminating this variation leads to an improvement of the quality of the product. SPC methods are helpful in deciding whether the production processes are stable or in a state of statistical control. Process control is achieved by employing control chart as a statistical tool. J HSHDG Control Limits, Specification Limits, and Natural Tolerance
(2014)45. Cost reduction is required for improving the Bottom line of the business. Understanding the RL cost equation will help to control and reduce unnecessary costs thereby positively impacting the bottom line. The RL management metrics need to be understood for real cost reduction. The RL cost equation takes into account the crucial cost elements associated with the creation, processing, handling and final disposition of the product returns.
Besides, when there had happened breakdowns, repair the system rapidly or immediately. Next, maintain optimal product mixes in order to achieve desired output in less cost. Linear programming can be used to measure the optimal blends of inputs. To make the system to be successful, the company has to reduce the problems of quality. Quality problem is an important issue that might cause the shutdowns.
Value analysis: Value analysis is the study of products manufacturing, marketing and designed for the purpose of more cost-effective production. Value Analysis is one of the major methods of cost reduction and cost control. All the products of Yamaha are manufactured with the goals of fulfilling the needs of the customers in value analysis. As it is the process in which the components are broken in to different parts thus each part can supportively be examined for efficiency and effectiveness. The limitations are: Lack of motivation Resistive to change Lack of knowledge Lack of patience Value engineering: Value engineering is a method to improve the value of goods and services.