Implementing Lean Manufacturing in the National Carton Industry Company
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Date
2016
Authors
Ahd Menawi
Hala Kharouf
Safad Ishtehy
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Abstract
In general Lean manufacturing principles have been successfully applied to manufactured products for several decades. It significantly reduces wastes in the supply chain and increases productivity as well as the quality of the products. The study described in this project is concerned with the implementation of lean manufacturing in a local factory. It investigates the importance of applying lean thinking to improve the operations efficiency and utilization in manufacturing companies. Oslo discusses the lean manufacturing concept, problem definition and the solution techniques that can be used towards this end. So lean manufacturing is a systemic method for the elimination of waste ("Muda") within a manufacturing process. It focuses on elimination non-value added activities and the efficiency of the overall system. Lean manufacturing is a manufacturing philosophy that shortens the time between the customer order and the product build/shipment by eliminating sources of waste. Waste is anything that does not contribute to transforming a part to your customers needs. A lean system can produce higher quality product, in lower quantities, with less committed inventory, with shorter lead time, at lower costs. The National carton industry company has different problems with inventory, safety and lead time between operations resulted from not having effective material handling system that leads to the delay of the production process and poor facility layout. We are going to study and analyze the implementation of the lean manufacturing process. Different lean tools can be used such as Value Stream Mapping (VSM),fish pone diagram and 5s . Recording to these problem the main goal of this project is to develop a theoretical lean thinking framework for implementing lean tools in the carton industry company. This will help the managers to understand the ways in which different lean principles may be incorporated into the production process. The objectives of this phase are to reduce inventory, minimize the lead time, remove non-added value activities and improve the factory layout We present the methodology that should be followed in order to implement the lean manufacturing in a local factory. We will divide the area of the factory into three main regions; Marketing, production and administration regions. We collect the data after making several field visits within two months. Then, we used various lean tools such as 5S, VSM. ,fish pone diagram in order to search for realistic solution for the facility. 1- Fish pone A fishbone diagram, also called a cause and effect diagram or Ishikawa diagram, is a visualization tool for categorizing te potential causes of a problem in order to identify its roots cause. Fishbone diagrams are used in the "analyze" phase of Six Sigma's DMAIC (define, measure, analyze, improve, control) approach to problem solving. It has the category such that people, machine, methods , measurement, environment , material . 2- Value stream mapping value stream mapping we draw current value stream mapping by using stander symbols throw this draw we clarify the information flow and details for each process in terms of cycle time number of worker added value number of shift in addition to specify the places of work in process and it's needed times , which helped us to calculate total led time added value and non-added value time in order to decrease time waste this improvement obviously appear in future value stream mapping According to these tool we can draw the current value stream mapping and reach to needed goal .
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