Lean Manufacturing Principles For Process Time Reduction In Conveyor Pulley Manufacturing Case Study
Application of Lean Manufacturing Principles for Process Time Reduction in Conveyor Pulley Manufacturing
Shyam Rangrej1, Kaustubh Samvatsar1, Pinkal Rana1, Purvi Chauhan2,
Saurin Sheth3
1UG Students of Production Engineering Department, 2Assistant Professor
Birla Vishvakarma Mahavidyalaya, Production Engineering Department,
V.V.NAGAR-388120 Birla Vishvakarma Mahavidyalaya,
E-mail: shyamrang24@gmail.com V.V.NAGAR-388120 E-mail:pdchauhan@bvmengineering.ac.in
3Associate Professor Mechatronics Engineering Department, GCET , V.V.NAGAR-388120 E-mail:saurinsheth@gcet.ac.in
Abstract: An exploratory study for the production system must be conducted to identify pertinent …show more content…
Lean Manufacturing process has three key stages. [1] The initial stage is to identify waste. According to the Lean philosophy, waste always exists and it can always be attempted to reduce it. This continuous improvement is known as Kaizen. One of the vital tools used to find this waste is a Value Stream Map (VSM). This shows how materials and processes flow through the organization for complete manufacturing of the product. It looks at how actions and departments are inter-connected and it highlights the …show more content…
For each waste identified in the first stage, Root Cause Analysis can be performed. Other effective tools for finding a root cause include Fish-bone Diagrams and Brainstorming. The final stage is to resolve the root cause and repeat the cycle. Using an appropriate problem-solving process, finalising the decision must that be done to fix the issue for increasing efficiency.
Continuous improvement by eliminating seven types of wastes mainly waste from overproduction, waiting time, transportation, processing, inventory, motion and defective production. It has even supported that the implementation structure reduces the setup time, overall cycle time and reduces manufacturing system divergence.[7]
3.0 PROBLEM DESCRIPTION & METHODOLOGY Time for every operation for conveyor pulley manufacturing was monitored. Fig 1 shows motion of conveyor pulley in the plant. Table 1 shows cycle time in marking, handling, machining, welding of the shell and turbo machining of the conveyor pulley in existing layout of the company. The crane speed is kept constant throughout (0.667 m/s).
Existing Layout:
Fig 1.Existing Layout
Table 1. Motion loss in existing
Shyam Rangrej1, Kaustubh Samvatsar1, Pinkal Rana1, Purvi Chauhan2,
Saurin Sheth3
1UG Students of Production Engineering Department, 2Assistant Professor
Birla Vishvakarma Mahavidyalaya, Production Engineering Department,
V.V.NAGAR-388120 Birla Vishvakarma Mahavidyalaya,
E-mail: shyamrang24@gmail.com V.V.NAGAR-388120 E-mail:pdchauhan@bvmengineering.ac.in
3Associate Professor Mechatronics Engineering Department, GCET , V.V.NAGAR-388120 E-mail:saurinsheth@gcet.ac.in
Abstract: An exploratory study for the production system must be conducted to identify pertinent …show more content…
Lean Manufacturing process has three key stages. [1] The initial stage is to identify waste. According to the Lean philosophy, waste always exists and it can always be attempted to reduce it. This continuous improvement is known as Kaizen. One of the vital tools used to find this waste is a Value Stream Map (VSM). This shows how materials and processes flow through the organization for complete manufacturing of the product. It looks at how actions and departments are inter-connected and it highlights the …show more content…
For each waste identified in the first stage, Root Cause Analysis can be performed. Other effective tools for finding a root cause include Fish-bone Diagrams and Brainstorming. The final stage is to resolve the root cause and repeat the cycle. Using an appropriate problem-solving process, finalising the decision must that be done to fix the issue for increasing efficiency.
Continuous improvement by eliminating seven types of wastes mainly waste from overproduction, waiting time, transportation, processing, inventory, motion and defective production. It has even supported that the implementation structure reduces the setup time, overall cycle time and reduces manufacturing system divergence.[7]
3.0 PROBLEM DESCRIPTION & METHODOLOGY Time for every operation for conveyor pulley manufacturing was monitored. Fig 1 shows motion of conveyor pulley in the plant. Table 1 shows cycle time in marking, handling, machining, welding of the shell and turbo machining of the conveyor pulley in existing layout of the company. The crane speed is kept constant throughout (0.667 m/s).
Existing Layout:
Fig 1.Existing Layout
Table 1. Motion loss in existing