Search results for: manufacturing efficiency

Authors: Takashi Kaminagayoshi, Shigeyuki Haruyama

Abstract:

To improve the manufacturing efficiency of biologics, such as antibody drugs, a quality engineering framework was designed. Within this framework, critical steps and parameters in the manufacturing process were studied. Identification of these critical steps and critical parameters allows a deeper understanding of manufacturing capabilities, and suggests to process development department process control standards based on actual manufacturing capabilities as part of a PDCA (plan-do-check-act) cycle. This cycle can be applied to each manufacturing process so that it can be standardized, reducing the time needed to establish each new process.

Keywords: Antibody drugs, biologics, manufacturing efficiency, PDCA cycle, quality engineering.

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Authors: Raed EL-Khalil, Hussein Zeaiter

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Managing and improving efficiency in the current highly competitive global automotive industry demands that those companies adopt leaner and more flexible systems. During the past 20 years the domestic automotive industry in North America has been focusing on establishing new management strategies in order to meet market demands. The lean management process also known as Toyota Manufacturing Process (TPS) or lean manufacturing encompasses tools and techniques that were established in order to provide the best quality product with the fastest lead time at the lowest cost. The following paper presents a study that focused on improving labor efficiency at one of the Big Three (Ford, GM, Chrysler LLC) domestic automotive facility in North America. The objective of the study was to utilize several lean management tools in order to optimize the efficiency and utilization levels at the “Pre- Marriage” chassis area in a truck manufacturing and assembly facility. Utilizing three different lean tools (i.e. Standardization of work, 7 Wastes, and 5S) this research was able to improve efficiency by 51%, utilization by 246%, and reduce operations by 14%. The return on investment calculated based on the improvements made was 284%.

Keywords: Lean Manufacturing, Standardized Work, Operation Efficiency and Utilization, Operations Management.

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Authors: B. Fahimnia, L.H.S. Luong, B. Motevallian, R. M. Marian, M. M. Esmaeil

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Product Lead Time (PLT) is the period of time from receiving a customer's order to delivering the final product. PLT is an indicator of the manufacturing controllability, efficiency and performance. Due to the explosion in the rate of technological innovations and the rapid changes in the nature of manufacturing processes, manufacturing firms can bring the new products to market quicker only if they can reduce their PLT and speed up the rate at which they can design, plan, control, and manufacture. Although there is a substantial body of research on manufacturing relating to cost and quality issues, there is no much specific research conducted in relation to the formulation of PLT, despite its significance and importance. This paper analyzes and formulates PLT which can be used as a guideline for achieving the shorter PLT. Further more this paper identifies the causes of delay and factors that contributes to the increased product lead-time.

Keywords: Manufacturing Control, Manufacturing Lead Time, Manufacturing Planning, Product Design, and Product Lead Time.

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Authors: Hudli Mohd. Rameez, K.H.Inamdar

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Many organisations are nowadays interested to adopt lean manufacturing strategy that would enable them to compete in this competitive globalisation market. In this respect, it is necessary to assess the implementation of lean manufacturing in different organisations so that the important best practices can be identified. This paper describes the development of key areas which will be used to assess the adoption and implementation of lean manufacturing practices. There are some key areas developed to evaluate and reduce the most optimal projects so as to enhance their production efficiency and increase the purpose of the economic benefits of the manufacturing unit. Lean manufacturing is becoming lean enterprise by treating its customers and suppliers as partners. This gives the extra edge in today-s cost and time competitive markets. The organisation is becoming strong in all the conventional competition points. They are Price, Quality and Delivery. Lean enterprise owners can deliver high quality products quickly, with low price.

Keywords: Competitive points, implementation, Leanmanufacturing, tools and techniques

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Authors: Esther T. Akinlabi, Rasheedat M. Mahamood, Mukul Shukla, Sisa. Pityana

Abstract:

The study of effect of laser scanning speed on material efficiency in Ti6Al4V application is very important because unspent powder is not reusable because of high temperature oxygen pick-up and contamination. This study carried out an extensive study on the effect of scanning speed on material efficiency by varying the speed between 0.01 to 0.1m/sec. The samples are wire brushed and cleaned with acetone after each deposition to remove un-melted particles from the surface of the deposit. The substrate is weighed before and after deposition. A formula was developed to calculate the material efficiency and the scanning speed was compared with the powder efficiency obtained. The results are presented and discussed. The study revealed that the optimum scanning speed exists for this study at 0.01m/sec, above and below which the powder efficiency will drop

Keywords: Additive Manufacturing, Laser Metal Deposition Process, Material efficiency, Processing Parameter, Titanium alloy.

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Authors: Takahiro Togawa, Nguyen Huu Phuc, Shigeyuki Haruyama, Oke Oktavianty

Abstract:

Our research focuses on a framework which analyses the relationship between product/process architecture, manufacturing organizational capability and manufacturing "implicit competitiveness" in order to improve manufacturing implicit competitiveness. We found that 1) there is a relationship between architecture-based manufacturing organizational capability and manufacturing implicit competitiveness, and 2) analysis and measures conducted in manufacturing organizational capability proved effective to improve manufacturing implicit competitiveness.

Keywords: Implicit competitiveness, QCD, Monozukuri capability.

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Authors: Jung-Lo Park, Sung-Sik Kim, Sun-Young Choi, Ju-Hyung Kim, Jae-Jun Kim

Abstract:

Sub-prime mortgage crisis which began in the US is regarded as the most economic crisis since the Great Depression in the early 20th century. Especially, hidden problems on efficient operation of a business were disclosed at a time and many financial institutions went bankrupt and filed for court receivership. The collapses of physical market lead to bankruptcy of manufacturing and construction businesses. This study is to analyze dynamic efficiency of construction businesses during the five years at the turn of the global financial crisis. By discovering the trend and stability of efficiency of a construction business, this study-s objective is to improve management efficiency of a construction business in the ever-changing construction market. Variables were selected by analyzing corporate information on top 20 construction businesses in Korea and analyzed for static efficiency in 2008 and dynamic efficiency between 2006 and 2010. Unlike other studies, this study succeeded in deducing efficiency trend and stability of a construction business for five years by using the DEA/Window model. Using the analysis result, efficient and inefficient companies could be figured out. In addition, relative efficiency among DMU was measured by comparing the relationship between input and output variables of construction businesses. This study can be used as a literature to improve management efficiency for companies with low efficiency based on efficiency analysis of construction businesses.

Keywords: Construction Company, DEA, DEA/Window, Efficiency Analysis

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Authors: Peter Kostal, Karol Velisek

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Flexible manufacturing system is a system that is able to respond to changed conditions. In general, this flexibility is divided into two key categories and several subcategories. The first category is the so called machine flexibility which enables to make various products by the given machinery. The second category is routing flexibility enabling to execute the same operation by various machines. Flexible manufacturing systems usually consist of three main parts: CNC machine tools, transport system and control system. A higher level of flexible manufacturing systems is represented by the so called intelligent manufacturing systems.

Keywords: drawing-free manufacturing, flexible manufacturing system, industrial robot, material flow.

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Authors: Williams S. Ebhota, Ckikaodili Virginia Ugwu

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Human ability is a major source of constraint to manufacturing industries in Nigeria. This paper therefore, discusses the importance of human influences on manufacturing and consequently to industrialization and National development. In this paper, the development of manufacturing was anchored on two main factors; Infrastructural Capacity Development (ICD) and Human Capacity Development (HCD). However, a wider view was given to the HCD and the various contemporary human capacity issues militating against manufacturing in Nigeria. It went further to discuss various ways of acquiring and upgrading workers’ skills and finally, suggestions were made on how to tackle the onerous human capacity issues in manufacturing.

Keywords: Manufacturing, Human, Capacity, Development, Innovation.

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Authors: Aigerim Uyzbayeva, Valeriya Tyo, Nurlan Ibrayev

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Kazakhstan is currently one of the dynamically developing states in its region. The stable growth in all sectors of the economy leads to a corresponding increase in energy consumption. Thus country consumes significant amount of energy due to the high level of industrialisation and the presence of energy-intensive manufacturing such as mining and metallurgy which in turn leads to low energy efficiency. With allowance for this the Government has set several priorities to adopt a transition of Republic of Kazakhstan to a “green economy”. This article provides an overview of Kazakhstan’s energy efficiency situation in for the period of 1991- 2014. First, the dynamics of production and consumption of conventional energy resources are given. Second, the potential of renewable energy sources is summarised followed by the description of GHG emissions trends in the country. Third, Kazakhstan’ national initiatives, policies and locally implemented projects in the field of energy efficiency are described.

Keywords: Energy efficiency in Kazakhstan, greenhouse gases, renewable energy, sustainable development.

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Authors: Hendry Muljadi, Hideaki Takeda, Koichi Ando

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A manufacturing feature can be defined simply as a geometric shape and its manufacturing information to create the shape. In a feature-based process planning system, feature library that consists of pre-defined manufacturing features and the manufacturing information to create the shape of the features, plays an important role in the extraction of manufacturing features with their proper manufacturing information. However, to manage the manufacturing information flexibly, it is important to build a feature library that can be easily modified. In this paper, the implementation of Semantic Wiki for the development of the feature library is proposed.

Keywords: Manufacturing feature, feature library, feature ontology, process planning, Wiki, MediaWiki, Semantic Wiki.

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Authors: M. Rahou, F. Sebaa, A. Cheikh

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Manufacturing tolerancing is intended to determine the intermediate geometrical and dimensional states of the part during its manufacturing process. These manufacturing dimensions also serve to satisfy not only the functional requirements given in the definition drawing, but also the manufacturing constraints, for example geometrical defects of the machine, vibration and the wear of the cutting tool. The choice of positioning has an important influence on the cost and quality of manufacture. To avoid this problem, a two-step approach has been developed. The first step is dedicated to the determination of the optimum position. As for the second step, a study was carried out for the tightening effect on the tolerance interval.

Keywords: Dispersion, tolerance, manufacturing, position.

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Authors: S. P. Singh

Abstract:

This paper measures technical and scale efficiencies of 40 Indian sugar companies for the period from 2004-05 to 2013-14. The efficiencies are estimated through input-oriented DEA models using one output variable—value of output (VOP) and five input variables—capital cost (CA), employee cost (EMP), raw material (RW), energy & fuel (E&F) and other manufacturing expenses (OME). The sugar companies are classified into integrated and non-integrated categories to know which one achieves higher level of efficiency. Sources of inefficiency in the industry are identified through decomposing the overall technical efficiency (TE) into pure technical efficiency (PTE) and scale efficiency (SE). The paper also estimates input-reduction targets for relatively inefficient companies and suggests measures to improve their efficiency level. The findings reveal that the TE does not evince any trend rather it shows fluctuations across years, largely due to erratic and cyclical pattern of sugar production. Further, technical inefficiency in the industry seems to be driven more by the managerial inefficiency than the scale inefficiency, which implies that TE can be improved through better conversion of inputs into output.

Keywords: Sugar industry, companies, technical efficiency, data envelopment analysis, targets.

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Authors: Olaniyi O. Omoyajowo

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To be successful in today’s competitive global environment, manufacturing industry must be able to respond quickly to changes in technology. These changes in technology introduce new risks and hazards. The management of risk/hazard in a manufacturing process recommends method through which the success rate of an organization can be increased. Thus, there is a continual need for manufacturing industries to invest significant amount of resources in risk management, which in turn optimizes the production output and profitability of any manufacturing industry (if implemented properly). To help improve the existing risk prevention and mitigation practices in Small and Medium Enterprise (SME) in Nigeria Manufacturing Industries (NMI), the researcher embarks on this research to develop a systematic Risk Management process.

Keywords: Manufacturing industries, production output, risk, risk management, SMEs.

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Authors: Justyna Rybicka, Ashutosh Tiwari, Shane Enticott

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In the age of automation and computation aiding manufacturing, it is clear that manufacturing systems have become more complex than ever before. Although technological advances provide the capability to gain more value with fewer resources, sometimes utilisation of the manufacturing capabilities available to organisations is difficult to achieve. Flexible manufacturing systems (FMS) provide a unique capability to manufacturing organisations where there is a need for product range diversification by providing line efficiency through production flexibility. This is very valuable in trend driven production set-ups or niche volume production requirements. Although FMS provides flexible and efficient facilities, its optimal set-up is key in achieving production performance. As many variables are interlinked due to the flexibility provided by the FMS, analytical calculations are not always sufficient to predict the FMS’ performance. Simulation modelling is capable of capturing the complexity and constraints associated with FMS. This paper demonstrates how discrete event simulation (DES) can address complexity in an FMS to optimise the production line performance. A case study of an automotive FMS is presented. The DES model demonstrates different configuration options depending on prioritising objectives: utilisation and throughput. Additionally, this paper provides insight into understanding the impact of system set-up constraints on the FMS performance and demonstrates the exploration into the optimal production set-up.

Keywords: Automotive, capacity performance, discrete event simulation, flexible manufacturing system.

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Authors: S. Kreitlein, N. Eder, A. Syed-Khaja, J. Franke

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The importance of energy efficiency within the production processes increases steadily. For a comprehensive assessment of energy efficiency within the production process, unfortunately no tools exist or have been developed yet. Therefore the Institute for Factory Automation and Production Systems at the Friedrich-Alexander-University Erlangen-Nuremberg has developed two methods with the goal of achieving transparency and a quantitative assessment of energy efficiency namely EEV (Energy Efficiency Value) and EPE (Energetic Process Efficiency). This paper describes the basics and state-of-the-art as well as the developed approaches.

Keywords: Energy efficiency, energy efficiency value, energetic process efficiency, production.

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Authors: Naveen Virmani, Rajeev Saha, Rajeshwar Sahai

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In today’s market, striving hard has become necessary for the industries to survive due to the intense competition and globalization. In earlier days, there were few sellers and limited numbers of buyers, so customers were having fewer options to buy the product. But today, the market is highly competitive and volatile. Industries are focusing on robotics, advance manufacturing methods like AJM (Abrasive Jet Machining), EDM (Electric Discharge Machining), ECM (Electrochemical Machining) etc., CAD/CAM, CAE to make quality products and market them in shortest possible time. Leagile manufacturing system is ensuring best available solution at minimum cost to meet the market demand. This paper tries to assimilate the concept of Leagile manufacturing system in today’s scenario and evaluating key factors affecting Leagile manufacturing using digraph technique.

Keywords: Agile manufacturing, digraph, lean manufacturing, leagile manufacturing.

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Authors: Rudi Kurniawan Arief

Abstract:

Manufacturing cost and setup time are the hot topics to improve in Metal Stamping industry because material and components price are always rising up while costumer requires to cut down the component price year by year. The Single Minute Exchange of Die (SMED) is one of many methods to reduce waste in stamping industry. The Japanese Quick Die Change (QDC) dies system is one of SMED systems that could reduce both of setup time and manufacturing cost. However, this system is rarely used in stamping industries. This paper will analyze how deep the QDC dies system could reduce setup time and the manufacturing cost. The research is conducted by direct observation, simulating and comparing of QDC dies system with conventional dies system. In this research, we found that the QDC dies system could save up to 35% of manufacturing cost and reduce 70% of setup times. This simulation proved that the QDC die system is effective for cost reduction but must be applied in several parallel production processes.

Keywords: Press die, metal stamping, quick die change, QDC system, single minute exchange die, manufacturing cost saving, SMED.

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Authors: Hossein Ali Akbarpour, Fatemeh Dadkhah

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This paper considers a multi criteria cell formation problem in Cellular Manufacturing System (CMS). Minimizing the number of voids and exceptional elements in cells simultaneously are two proposed objective functions. This problem is an Np-hard problem according to the literature, and therefore, we can-t find the optimal solution by an exact method. In this paper we developed two ant algorithms, Ant Colony Optimization (ACO) and Max-Min Ant System (MMAS), based on Data Envelopment Analysis (DEA). Both of them try to find the efficient solutions based on efficiency concept in DEA. Each artificial ant is considered as a Decision Making Unit (DMU). For each DMU we considered two inputs, the values of objective functions, and one output, the value of one for all of them. In order to evaluate performance of proposed methods we provided an experimental design with some empirical problem in three different sizes, small, medium and large. We defined three different criteria that show which algorithm has the best performance.

Keywords: Ant algorithm, Cellular manufacturing system, Data envelopment analysis, Efficiency

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Authors: Ijaz Ul Haq, Fiorenzo Franceschini

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The distributed manufacturing methodology brings a new concept of decentralized manufacturing operations close to the proximity of end users. A preliminary scale, to measure distributed capacity and evaluate positioning of firms, is developed in this research. In the first part of the paper, a literature review has been performed which highlights the explorative nature of the studies conducted to present definitions and classifications due to novelty of this topic. From literature, five dimensions of distributed manufacturing development stages have been identified: localization, manufacturing technologies, customization and personalization, digitalization and democratization of design. Based on these determinants a conceptual scale is proposed to measure the status of distributed manufacturing of a generic firm. A multiple case study is then conducted in two steps to test the conceptual scale and to identify the corresponding level of distributed potential in each case study firm.

Keywords: Conceptual scale, distributed manufacturing, firm’s distributed capacity, manufacturing continuum.

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Authors: Hendry Muljadi, Hideaki Takeda, Koichi Ando

Abstract:

A manufacturing feature can be defined simply as a geometric shape and its manufacturing information to create the shape. In a feature-based process planning system, feature library plays an important role in the extraction of manufacturing features with their proper manufacturing information. However, to manage the manufacturing information flexibly, it is important to build a feature library that is easy to modify. In this paper, a Wiki-based feature library is proposed.

Keywords: Manufacturing feature, feature library, feature ontology, process planning, Wiki, MediaWiki.

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Authors: Guenther Schuh, Sebastian Woelk, Daniel Schraknepper, Anders Such

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The systematic evaluation of manufacturing technologies with regard to the potential for product designing constitutes a major challenge. Until now, conventional evaluation methods primarily consider the costs of manufacturing technologies. Thus, the potential of manufacturing technologies for achieving additional product design features is not completely captured. To compensate this deficit, final evaluations of new technologies are mainly intuitive in practice. Therefore, an additional evaluation dimension is needed which takes the potential of manufacturing technologies for specific realizable product designs into account. In this paper, we present the approach of an evaluation method for selecting manufacturing technologies with regard to their potential for product designing. This research is done within the Fraunhofer innovation cluster »AdaM« (Adaptive Manufacturing) which targets the development of resource efficient and adaptive manufacturing technology processes for complex turbomachinery components.

Keywords: Manufacturing, product design, production, technology assessment, technology management.

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Authors: Naveen Virmani, Rajeev Saha, Rajeshwar Sahai

Abstract:

There is drastic change in manufacturing era in last two decades. It has become mandatory for the industries to become aware of latest and advanced manufacturing technologies and strategies. Leagile manufacturing focuses on minimizing the wastes and meeting customers’ requirements in minimum time possible. However, it becomes difficult to implement all leagile tools simultaneously in industry. In this paper, 17 main criteria of leagile manufacturing have been found and DEMATEL (Decision Making Trial and Evaluation Laboratory) approach has been applied to analyze importance of criteria and casual relations among these criteria.

Keywords: Agile, DEMATEL approach, lean, leagile manufacturing.

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Authors: Kittipong Tissayakorn, Fumio Akagi, Yu Song

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Manufacturers have been exploring innovative strategies to achieve and sustain competitive advantages as they face a new era of intensive global competition. Such strategy is known as Supply Chain Management (SCM), which has gained a tremendous amount of attention from both researchers and practitioners over the last decade. Supply chain management (SCM) is considered as the most popular operating strategy for improving organizational competitiveness in the twenty-first century. It has attracted a lot of attention recently due to its role involving all of the activities in industrial organizations, ranging from raw material procurement to final product delivery to customers. Well-designed supply chain systems can substantially improve efficiency and product quality, and eventually enhance customer satisfaction and profitability. In this paper, a manufacturing engineering perspective on supply chain integration is presented. Research issues discussed include the product and process design for the supply chain, design evaluation of manufacturing in the supply chain, agent-based techniques for supply chain integration, intelligent information for sharing across the supply chain, and a development of standards for product, process, and production data exchange to facilitate electronic commerce. The objective is to provide guidelines and references for manufacturing engineers and researchers interested in supply chain integration.

Keywords: Supply Chain, Supply Chain Management, Supply Chain Integration, Manufacturing Industries.

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Authors: Sue-Yi Chen, Wei-Chun Hsu, Jon-Yiew Gan

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Si-based double-junction tandem solar cells have become a popular research topic because of the advantages of low manufacturing cost and high energy conversion efficiency. However, there is no set of calculations to select the appropriate top cell materials. Therefore, this paper will propose a simple but practical selection method. First of all, we calculate the S-Q limit and explain the reasons for developing tandem solar cells. Secondly, we calculate the theoretical energy conversion efficiency of the double-junction tandem solar cells while combining the commercial monocrystalline Si and materials' practical efficiency to consider the actual situation. Finally, we conservatively conclude that if considering 75% performance of the theoretical energy conversion efficiency of the top cell, the suitable bandgap energy range will fall between 1.38 eV to 2.5 eV. Besides, we also briefly describe some improvements of several proper materials, CZTS, CdSe, Cu2O, ZnTe, and CdS, hoping that future research can select and manufacture high-efficiency Si-based tandem solar cells based on this paper successfully. Most importantly, our calculation method is not limited to silicon solely. If other materials’ performances match or surpass silicon's ability in the future, researchers can also apply this set of deduction processes.

Keywords: High-efficiency solar cells, material selection, Si-based double-junction solar cells, tandem solar cells, photovoltaics.

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Authors: Wan Hasrulnizzam Wan Mahmood, Mohd Nizam Ab Rahman, Baba Md Deros

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Green supply chain management is an increasingly recognized practice among companies that are seeking to improve environmental performance. Of particular concern is how to arouse organizational awareness and put green activities into practice in order to enhance manufacturing performances. This paper investigates the correlation of green supply chain practices and manufacturing performances in Malaysian certified MS ISO 14000 manufacturing firms. The findings shows that green supply chain practices which that can be denominated product recycling, environmental compliance and optimization have significant influence to some of the manufacturing performances.

Keywords: Green supply chain practice, Manufacturing system performance, Malaysia

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Authors: Radovan Holubek, Daynier Rolando Delgado Sobrino, Roman Ruzarovsky

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Current trends in manufacturing are characterized by production broadening, innovation cycle shortening, and the products having a new shape, material and functions. The production strategy focused on time needed change from the traditional functional production structure to flexible manufacturing cells and lines. Production by automated manufacturing system (AMS) is one of the most important manufacturing philosophies in the last years. The main goals of the project we are involved in lies on building a laboratory in which will be located a flexible manufacturing system consisting of at least two production machines with NC control (milling machines, lathe). These machines will be linked to a transport system and they will be served by industrial robots. Within this flexible manufacturing system a station for the quality control consisting of a camera system and rack warehouse will be also located. The design, analysis and improvement of this manufacturing system, specially with a special focus on the communication among devices constitute the main aims of this paper. The key determining factors for the manufacturing system design are: the product, the production volume, the used machines, the disposable manpower, the disposable infrastructure and the legislative frame for the specific cases.

Keywords: Paperless manufacturing, flexible manufacturing, robotized manufacturing, material flow, iCIM.

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Authors: Adithya Nadig

Abstract:

In the field of production, characterization of surface roughness plays a vital role in assessing the quality of a manufactured product. The defined parameters for this assessment, each, have their own drawbacks in describing a profile surface. From the purview of small-scale and medium-scale industries, an increase in time spent for manual inspection of a product for various parameters adds to the cost of the product. In order to reduce this, a uniform and established standard is necessary for quantifying a profile of a manufactured product. The inspection procedure in the small and medium-scale manufacturing units at Jigani Industrial area, Bangalore, was observed. The parameters currently in use in those industries are described in the paper and a change in the inspection method is proposed.

Keywords: Efficiency of quality assessment, areal profiling technique, manufacturing, standardization, Surface Roughness Characterization.

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Authors: R. Oonsivilai, M. Oonsivilai, J. Sanguemrum, N. Thumsirirat, A. Oonsivilai

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Chaiyaphum Starch Co. Ltd. is one of many starch manufacturers that has introduced machinery to aid in manufacturing. Even though machinery has replaced many elements and is now a significant part in manufacturing processes, problems that must be solved with respect to current process flow to increase efficiency still exist. The paper-s aim is to increase productivity while maintaining desired quality of starch, by redesigning the flipping machine-s mechanical control system which has grossly low functional lifetime. Such problems stem from the mechanical control system-s bearings, as fluids and humidity can access into said bearing directly, in tandem with vibrations from the machine-s function itself. The wheel which is used to sense starch thickness occasionally falls from its shaft, due to high speed rotation during operation, while the shaft may bend from impact when processing dried bread. Redesigning its mechanical control system has increased its efficiency, allowing quality thickness measurement while increasing functional lifetime an additional 62 days.

Keywords: Control system, Machinery, Measurement, Potato starch

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Authors: Ahmad Yame, Ahad Ali, Badih Jawad, Daw Al-Werfalli Mohamed Nasser, Sabah Abro

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Industries in general have a lot of waste. Wool textile company, Baniwalid, Libya has many complex problems that led to enormous waste generated due to the lack of lean strategies, expertise, technical support and commitment. To successfully address waste at wool textile company, this study will attempt to develop a methodical approach that integrates lean manufacturing tools to optimize performance characteristics such as lead time and delivery. This methodology will utilize Value Stream Mapping (VSM) techniques to identify the process variables that affect production. Once these variables are identified, Design of Experiments (DOE) Methodology will be used to determine the significantly influential process variables, these variables are then controlled and set at their optimal to achieve optimal levels of productivity, quality, agility, efficiency and delivery to analyze the outputs of the simulation model for different lean configurations. The goal of this research is to investigate how the tools of lean manufacturing can be adapted from the discrete to the continuous manufacturing environment and to evaluate their benefits at a specific industrial.

Keywords: Lean manufacturing, DOE, value stream mapping, textiles.

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