Implementing Lean Manufacturing System In Siniora Food Company
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Date
2012
Authors
Sawsan Abbas
Neveen Abu Lawi
Sageda Dadu
Rawan Zahran
Ola Sabra
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Abstract
Lean Manufacturing is a strategy for achieving significant, continuous improvement in performance through the elimination of all waste of time and resources in the total business process. Elimination of waste means eliminating all activities that do not add value. (Buker Company, 2011) We are going to study and analyze the lean concepts in Saniora food company . Also to increase the awareness of the importance of lean in practice through the close collaboration with industry. Siniora Food Factory (SFF) has been suffering from different kinds of wastes appearing significantly in its various departments .In particular, the factory has significant amounts of wastes appearing in production and inventory As its products are perishable ones, we aim to reduce the various kinds and quantities of waste produced in its departments via implementing a lean manufacturing system in its plant .The implementation of such a system, as a result of eliminating wastes, helps the company improve its productivity, increase efficiency and cut excess inventories . In order to achive our objectives we followed a clear methodology represented in studying the current state of S.F.F , At the begining we are going to ideintify the sevesral types of of wastes , quantify these wastes then use pleanty of lean tools and other supporting tools such as : 5s , V.S.M , F.B.D . By using these tools we were able to analyze the available data , discovre the current problems in order to improve the future state for the factory . As a result of future point view included implemnting our project we conclude that if our recommendations and solutions will be implemented the quantits of waste will be decreased in terms of money and the storage area will be increased which lead us to achive our goals in the company. Solutions And Recommendation In order to achieve goals of our project that have been mentioned in CH.1, which aimed to implement lean manufacturing system by using plenty of lean tools and other supportive tools, after analysis that have been done in CH.5 we reached to realistic solutions and recommendations that covered all targeted departments (warehouse, production and maintenance) that aims to promote system effectively and its represented effectively in: Warehouses: Studying all suggested alternatives of layout and choosing the optimal solution from company's point view. Establishing a crane in the southern warehouse in order to facilitate arranging, entering and getting out materials in addition to facilitate workers motion. Get rid of empty cans through pressing them , send them back to the supplier or buying labeling machine in order to relabeling these cans. Specialize containers for Amman and Gaza products in order to have better utilization for cold cut warehouse and facilitate sorting all cold cut products. Position pierced shelves in the last room in cold cut warehouse. Clarify the responsibilities and job description for both maintenance and financial department. Replace the freezer ( ) with closed door to ensure high quality cooling process. Computerize the maintenance department and spare part warehouse by using barcode system to monitor the input/ output piece. Hanging boards for manual tool which facilitates reaching for these tool easily and efficiently. Proposals and solutions for reducing waste in production area: Document procedures which ensure continuous preventive maintenance includes all production lines . Developing workers programs in terms of : Modifying workers training program. Specify the responsibilities of each worker. Employing more workers if needed. Designing visual management boards for each production lines to clarify the followed instructions in production area. Increase number of pans if needed. Reformulation for contracts with raw meat suppliers to ensure better quality for raw meat packaging in order to facilitate peeling process. Rescheduling for production plans to keep up with demand. Set instructions to ensure workers commitment. Sorting workers on production lines based on their uniform. Feasibility study for ability of adding new Mincer. Purchasing number of trolleys and sticks. Purchasing two electronic calipers to facilitate diameter measuring process of poly clips products. Purchasing special device for measuring the required length of case speedily Purchasing more suitable balance with edges. Feasibility study for ability of adding new boiler . Ability to extent showering area in the direction of packaging room. Creating incentive program for packaging workers.