The Japanese automobile industry has been hit sharply by the economic downturn of recent decades. The rise in costs and decline in sales have led to serious problems in the auto industry. In order to address these issues, most companies engage in downsizing and redesigning production operations. It is crucial to investigate the time wasted by replacing assembly boards occurring in manufacturing lines. Therefore, the aim of this study was to provide an integrated approach, Teoriya Resheniya Izobreatatelskih Zadatch (TRIZ), to providing efficient solutions for the automobile industry. The first step of this methodology is to detail the technical problems using the Function and Attribute Analysis (FAA) model. Secondly, a contradiction matrix and the inventive principle were applied to find the solutions. In this study, an auto part supplier named Sumi-Hanel located in Hanoi, Vietnam, was taken as a case study; the empirical results showed that waste time had been reduced to 67%, nearly 8400 square meters was saved, and a 20% cost reduction was achieved by reusing old frames. The research proves that the combination of TRIZ and lean manufacturing successfully increases production performance and reduces waste due to technological advancements.
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