ppt-project-final.ppt
- 1. Title Applying lean manufacturing concepts in furniture factory: case study-based project. Supervised by: Dr. Moawia Ramadan Prepared by: Dina Hijab Majeda Hussain Musab Nazzal Shahd Saye d
- 2. Introduction • in project 1 we defined the problem in Aldajani factory as accumulation of huge amounts of waste, and we found that lean manufacturing technique is a successful way to solve this problem.
- 3. • The main objective of the project, is to apply many techniques of lean manufacturing techniques in Al-Dajani co. to remove / or reduce waste resulting from many sections that exist in the metal furniture factory. • So, we applied techniques like 5s, value stream map and cause-effect diagram) Definition and frame work
- 4. • We will start with the project using the methodology of “define, measure, analyze, improve and control” (DMAIC).
- 5. Measure • We measure some of the waste by the engineering sense (qualitative form) and some of them by specific tools like VSM (quantitative form).
- 6. Qualitative form • Motion waste. • Transportation waste. • Inventory waste. • Waiting waste. • Defects waste.
- 7. Type of waste Description Observed Motion 1 Poor workstation layout Yes 2 Shared equipment and machines Yes 3 Poor production planning Yes 4 Poor process design Yes Transportation 1 Poor layouts – large distance between operations Yes 2 Large Batch sizes No 3 Multiple storage facilities Yes Inventory 1 Overproduction of goods Yes 2 Inventory defects Yes 3 Huge amount of raw material Yes 4 Delays in production Yes Waiting 1 Unplanned downtime or Idle equipment Yes 2 Long or delayed set-up times No 3 Lack of process control No 4 Poor process communication Yes Defects 1 Poor quality control at the production level No 2 Poor machine repair Yes 3 Lack of process standards Yes 4 Not understanding your customers’ needs No
- 8. Quantitative form • Value stream map, is a technique to describe the current flow of a specific process • In the project we have taken a two door cabinet as a representative sample of the information flows and materials that occur in this factory, and we applied a value stream map on it.
- 10. Product family Current state drawing Future state drawing Work plan and implementation
- 11. To assess the performance of the company by using the VSM tool we collect these information: The number of working days per month 26 One shift lasts 8 hours break Half an hour Raw material requested Every six months
- 13. Analysis of current state map • We calculated the takt time, the process times, and waiting times (inventory lead times) and add these to our VSM. • Takt time = 24 min /unit • Inventory lead time = Inventory level*Takt time • The value-added activities in percentage of the processes = 6.77%
- 15. Analyze process capacity • Achieving balance between the customer’s demand and the capacity of the production process so that there is a balance between the time-specific operations for each process. Also, there must be a balance in the arrangement and sequencing of products so that we achieve a stable and predictable production pace.
- 16. • There are two steps to achieve this balance : 1. Compare the time it takes to make one piece with the takt time. 2. Assess the balance of the production processes, by comparing the time of each process with respect to the others, this helps to determine the potential bottlenecks for this process,
- 19. • We studied the bottleneck in order to calculate the maximum output. • maximum output = 3.2 unit • This means that the company can produce 3 pieces in the one-way tour instead of producing one piece. So they can produce 41 pieces. • In comparison with the customer’s request, it is possible to fulfill the request within two days in addition to the day of the paint.
- 21. The future state map 1. Move towards continuous flow (Kanban) “Flow where you can, pull where you must“ 2. Rebalancing the process 3. Kaizen (continuous improvement)
- 22. After analyzing the current situation of the company we set a specific steps for improvement. using our results, kaizen and kampan methods we draw a template for the future state map which shows the progress of the process after applying all the changes to it.
- 24. Recommendations: 1. Commitment to safety instructions, and keep aisles clear from obstacles Continuous cleaning for the workplace through following programmed cleaning schedule. 2. Maintain the arrangement of tools used in manufacturing operations. 3. Give workers standard operating procedures in order to reduce defects and increase productivity. 4. The necessity of employing an industrial engineer to follow up an application of lean system in order to improve quality and reduce wastes. 5. Improve the factory lighting system.
- 25. 6. Better production planning in order to reduce the excessive amount of inventory. 7. Using CNC method to cut the metallic boards in order to reduce waste. 8. making new products using the waste of material such as producing second hand tables or cabinet. 9. Improve their marketing skills to build bridges to reach customers’ needs and fulfill it. 10. Also there is no website showing their products and that is considered something important due to online purchasing.