Robust Design and Optimization of Production Wastes: An Application for Industries
Commenced in January 2007
Frequency: Monthly
Edition: International
Paper Count: 32870
Robust Design and Optimization of Production Wastes: An Application for Industries

Authors: Christopher C. Ihueze, Charles C. Okpala, Christian E. Okafor, Peter O. Ogbobe

Abstract:

This paper focuses on robust design and optimization of industrial production wastes. Past literatures were reviewed to case study Clamason Industries Limited (CIL) - a leading ladder-tops manufacturer. A painstaking study of the firm-s practices at the shop floor revealed that Over-production, Waiting time, Excess inventory, and Defects are the major wastes that are impeding their progress and profitability. Design expert8 software was used to apply Taguchi robust design and response surface methodology in order to model, analyse and optimise the wastes cost in CIL. Waiting time and overproduction rank first and second in contributing to the costs of wastes in CIL. For minimal wastes cost the control factors of overproduction, waiting-time, defects and excess-inventory must be set at 0.30, 390.70, 4 and 55.70 respectively for CIL. The optimal value of cost of wastes for the months studied was 22.3679. Finally, a recommendation was made that for the company to enhance their profitability and customer satisfaction, they must adopt the Shingeo Shingo-s Single Minute Exchange of Dies (SMED), which will immediately tackle the waste of waiting by drastically reducing their setup time.

Keywords: Excess-inventory, setup time, single minute exchange of dies, optimal value, over-production, robust design.

Digital Object Identifier (DOI): doi.org/10.5281/zenodo.1334600

Procedia APA BibTeX Chicago EndNote Harvard JSON MLA RIS XML ISO 690 PDF Downloads 1691

References:


[1] Womack, J. Jones, D. and Roos, D. (1990) The Machine that Changed the World Rawson Associates, New York, USA.
[2] Hunter, S. (2003). An Introduction to Lean Production Systems. FDM Journal, Vol. 75, Iss.13; pg. 58.
[3] Ihueze, C. and Okpala, C. (2012). Application of Taguchi Robust Design as Optimized Lean Production in Manufacturing Companies. Research Journal in Engineering and Applied Sciences http://rjeas.emergingresource.org/issuesview.php?id=100&issue_name= Volume%201%20Number%201&issue_month=January&issue_year=20 12.
[4] Taguchi, G. (1987). The Taguchi Approach to Parameter Design. Quality Progress Publications, Okinawa, Japan.
[5] Ihueze, C.C., Obiuto, C.C., and Okpala, C.C. (2012), "Quality improvement of process product value through robust design of control parameters" Research journal in Engineering and Applied sciences (1), 2012, 70-76.
[6] Montgomery, D.C. (2009). Design and Analysis of Experiments; 7th edition. Hoboken, NJ: Wiley.
[7] Box GEP, Wilson KB (1951). "On the Experimental attainment of Optimum Conditions" Journal of the Royal Statistical Society B, 13th Edition, 1-45.
[8] Montgomery, D.C. (2009). Design and Analysis of Experiments; 7th edition. Hoboken,NJ:Wiley.
[9] Hill WJ, Hunter WG (1989). "A Review of Response Surface Methodology: A literature Review." Technometrics, Vol 8, 571-590.
[10] Mead R, and Pike D J (1975) "A Review of Response Surface Methodology from a Biometric View Point" Biometrics Vol 31, No 4, 803-851.
[11] Obiuto C.C, (2012) M.Eng Thesis, Submitted to the Industrial and Production Engineering Department of Nnamdi Azikiwe University, Awka.
[12] Myers R H, Montgometry, D C, Anderson-Cook C M, (2009) "Response Surface Methodology: Process and product Optimization using Designed Experiments. John Wiley and Sons.
[13] Taguchi G., Elsayed A.E., Hsiang T.C., (1989) "Quality Engineering in Production Systems," McGraw-Hill book Company, New York.
[14] Taguchi G., Chowdhury S., Wu Y. (2004), "Taguchi-s Quality Engineering handbook," Edition 2004, pp. 21.
[15] Shinkle, G. Gooding, R. and Smith, M. (2004). Transforming Strategy Into Success: How to Implement a Lean Management System. Productivity Press, New York.
[16] Hines, P. (1994). Creating World Class Suppliers. Pitman Publishing, London, UK.
[17] Box, G., Bisgaard, S., and Fung, C. (1988). Quality Practices in Japan. Quality Progress Publications, Okinawa, Japan.
[18] Shingo, S. (1985). A Revolution in Manufacturing: The SMED System. Productivity Inc. USA.