Implementation of Lean Manufacturing Techniques at the National Company of the Aluminum and Profiles Industry (NAPCO)
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NAPCO Company is the first manufacturer of aluminum profiles in Palestine, it is established in 1991, located in the West Bank city of Nablus, it has an area of 28 thousand square-meter plant, operated by 185 employees, and it is managed by Eng. Anan Anabtawi, Mr. Haitham Hamed and Eng. Amjad Anabtawi. It is a subsidiary of Arab Palestine Investment Company (APIC). Also, it is equipped with three production lines of three families of product mill finish, powder coating and anodized with different cross sections and multiple color. NAPCO’s profile applications include doors, windows, curtain walls, kitchen cabinets, electrical and electronic cabinets and architectural features, this application make them able to meet the needs of the local market and access to regional markets (Jordan). Due to the nature of this vital industry in Palestine, the industry encounters large amounts of wastes generated from the multiple and sequence operations that need to high accuracy during production. More specifically, the well-known seven wastes - TIMWOOD- (transpiration, inventory, motion, waiting, over processing, over production and defects) are apparently generated in the industry. The project focuses on applying DMAIC methodology which is well-known tools of lean manufacturing philosophy using live or historical data in Aluminum powder coating department in NAPCO for the purpose of reducing/eliminating the potential wastes, improving efficiency, reducing manufacturing lead times and delivery delays and hence increasing customer satisfaction. Then, the potential root-causes of the identified wastes will be discovered by using the quality control tools such as control charts, Pareto charts for the causes of defect waste, cause and effect diagram for each type of waste at NAPCO and pie chart. The Performance will be measured before and after waste of defect reductions to ensure realization of improvements.