Search Results (8)

Due to the context of market competitiveness and the economic and financial crisis, companies need to optimize their production systems, tracking the raw material from the suppliers until the final product arrives to the consumer. The Lean philosophy assumes a relevant role for today’s industries through its concepts and tools, enabling optimization, increasing revenues, and having the principle of not expropriating the environment. This article aims to analyse the level of maturity reached by industries in Luanda regarding the practices and tools of the Lean philosophy. A Lean graphic model was built, measured by the Lean Enterprise Self-Assessment Tool (LESAT) maturity model through qualitative and quantitative research focusing on the statistics of 87 circumscribed industries at Viana Industrial Development Pole in the Economic Special Zone of Luanda region, Angola. Initially was conducted an analysis to see whether Lean practices and tools were used: 5S, OKJust-In-Time, Kanban, Bottleneck Analysis, Jidoka, Kaizen, Poka-Yoke, SMED, Gemba, Heijunka, Value Stream Mapping, Hoshin Kanri, and Andon. The next steps were to analyse the following: customer value analysis; value chain analysis; analysis of the use of the pulled production system; and analysis of the use of the continuous production flow analysis of continuous improvement. The result shows these industries using the Lean philosophy at a very low level of maturity. Only the 5S tool was known and used. The JIT, Kanban, and Bottleneck Analysis were moderately used. Only 50% of Lean practices were used. Full article

Shaping safe and hygienic working conditions is the basic obligation of the employer. Employers are still looking for methods, tools, and solutions to improve work safety. The study reviews the literature on solutions aimed at improving occupational safety in construction. For this purpose, bibliometric analysis was used, consisting of the exploration and analysis of scientific studies in the field of occupational health and safety, including the possibility of using the LM tool to improve working conditions on construction sites. The study presents the possibility of implementing Lean Manufacturing (LM) tools in the construction industry. Their strengths and weaknesses were identified, and the benefits and possible barriers related to their effective implementation/use were identified. The result of the analyses was a summary of benefits for the construction industry (strengths and opportunities) as well as areas requiring improvement (weaknesses and hazards) regarding the LM tools used. Based on the conducted analyses, it was found that it is possible to use the tools of the LM concept to improve work safety and organize tasks performed on construction sites. The implementation of LM tools, such as 5S/6S, Poka-Yoke, and Standardization, enables risk reduction through a direct impact on the area being analyzed, in which occupational hazards have been identified. It is also noted that there is a need to simultaneously use LM tools (VM, Gemba-Walk, DHM) as solutions aimed at reducing risk. Full article

Product assembly is often the last step in the manufacturing process. This task is usually performed by an assembly worker who needs to have practical experience and expertise. For complex products, the assembly may require a long time to study assembly plans. This paper presents a custom-designed Pick-to-Light system using Poka Yoke principles to make this activity easier. The created modular system with two-stage verification serves to guide the assembler precisely. It shows him on the display which parts he should use in a strictly defined assembly step. Our proposal aims to shorten assembly time and reduce the number of errors, which was supported by a case study in a small company with 30 employees. After analysing the data, we can declare that the proposed system significantly reduces the time required for assembly from 7 to 35% and reduces the error rate by 35%. The solution is scalable and flexible, as it can be easily adapted to display assembly steps for a different product. Full article

This study aims to address the challenge of implementing Lean philosophy in Small and Medium Enterprises (SMEs) and fill the research gap regarding Lean application in vehicle seat upholstery maintenance/repairing processes. The Lean tools applied in a case study of an upholstery industry of vehicle seats were as follows: Value Stream Mapping, Spaghetti Diagram, Gemba, 5S, Standardized Work, Kaizen, Kanban, and Poka-Yoke tools. A Decision Support Method using Excel Microsoft 365 was developed for improved stock control. A GUT Matrix was formulated to prioritize improvement opportunities, aiding prompt decision-making. This systematic approach enabled the company to address critical areas requiring swift attention. The results of Lean tools implementation led to a process waste minimization around 47%, and the process Lead Time decreased by approximately 26%, resulting in a 33% production increase. Thus, the Lean tools integration leads to substantial waste reduction, shorter process time, and increased production. The Decision Support Method enabled the company to efficiently monitor and manage its stock levels, thereby enhancing inventory management practices. This case study outlines the successful optimization of an upholstery production process in an SME by effectively applying Lean tools, highlighting its feasibility and benefits. Full article

European manufacturing companies are currently in a very difficult situation. On the one hand, they have to strive for sustainable development. On the other hand, they have to face problems related to the geopolitical situation and the pursuit of cleaner production (including restrictive regulations on emissions). A significant increase in electricity prices means that companies have to take steps to use electricity rationally without reducing the level of production or incurring other additional costs. In this study, attention was paid to the influence of quality tools (QTs) in production process (PP) management on increasing energy efficiency (EE). Based on the literature review, it was found that the most frequently described QTs, i.e., SMED, TPM, Six Sigma, SPC, FMEA, 5S, or Poka-Yoke, used to improve PP did not take into account their impact on the EE of the enterprises. Therefore, the main purpose of this study was to examine this correlation and show that QTs can be helpful in shaping the energy management system (EMS). Achieving the research goal was possible thanks to surveys carried out among manufacturing companies. Using statistical tests, the existence of a statistically significant correlation was proved between QTs and EMS elements. Full article

Background: Exploring the impact of combining Industry 4.0 technologies and Lean Manufacturing tools on organizational performance has been a popular topic in recent years. Design/Methodology/Approach: We propose a novel Smart and Sustainable Manufacturing System (SSMS) to provide management insights related to social impact, economic performance, and environmental impact. Some tools called Dynamic Lean 4.0 tools, such as Sustainable Value Steam Mapping (VSM), Extended Single Minute Exchange of Die (SMED), and Digital Poka-Yoke, are presented as outputs of synergistic relationships that optimize production processes. Originality/Research gap: There are few studies on the application of SSMS. This work presents a case study, aiming to fill this gap. A case study of vacuum degassing equipment fabrication is presented to demonstrate the improvement of utilizing the Define-Measure-Analyze-Improve-Control (DMAIC) method with Digital Poka-Yoke. Key statistical results: The implementation of this project increased the process capability index, Cpk, from 1.278 to 2. Practical Implications: It was concluded that the company successfully implemented a smart and sustainable manufacturing system, and created a safer working environment and new job opportunities, while increasing production yield from 99.44% to 100%, improving worker utilization, and directly saving NT$68,000. Limitations of the investigation: This paper is the use of a single case study. More applications of Dynamic Lean 4.0 tools in SSMS should be explored. Full article

In this paper, we present the re-engineering process of an assembly line that features speed reducers and multipliers for agricultural applications. The “as-is” line was highly inefficient due to several issues, including the age of the machines, a non-optimal arrangement of the shop floor, and the absence of process standards. The assembly line issues were analysed with Lean Manufacturing tools, identifying irregularities and operations that require effort (Mura), overload (Muri), and waste (Muda). The definition of the “to-be” line included actions to update the department layout, modify the assembly process, and design the line feeding system in compliance with the concepts of Golden Zone (i.e., the horizontal space more ergonomically and easily accessible by the operator) and Strike Zone (i.e., the vertical workspace setup in accordance to ergonomics specifications). The re-engineering process identified a critical problem in the incorrect assembly of the oil seals, mainly caused by the difficulty in visually identifying the correct side of the component, due to different reasons. Convolutional neural networks were used to address this issue. The proposed solution resulted to be a Poka Yoke. The whole re-engineering process induced a productivity increase that is estimated from 46% to 80%. The study demonstrates how Lean Manufacturing tools together with deep learning technologies can be effective in the development of smart manufacturing lines. Full article

To err is an intrinsic human trait, which means that human errors, at some point, are inevitable. Business improvement tools and practices neglect to deal with the root causes of human error; hence, they ignore certain design considerations that could possibly prevent or minimise such errors from occurring. Recognising this gap, this paper seeks to conceptualise a model that incorporates cognitive science literature based on a mistake-proofing concept, thereby offering a deeper, more profound level of human error analysis. An exploratory case study involving an aerospace assembly line was conducted to gain insights into the model developed. The findings of the case study revealed four different causes of human errors, as follows: (i) description similarity error, (ii) capture errors, (iii) memory lapse errors, and (iv) interruptions. Based on this analysis, error-proofing measures have been proposed accordingly. This paper lays the foundation for future work on the psychology behind human errors in the aerospace industry and highlights the importance of understanding human errors to avoid quality issues and rework in production settings, where labour input is of paramount importance. Full article