CHAPTER I INTODUCTION 1.Background The goal of research described application lean manufacturing to improving the manufacturing process on an assembly line in a car plant. Currently manufacturing process have so many disanvantagees,such as low efficiency, high cost, mass production quality is not stable, the accuracy is not high, and more labor and labor intensity,and these led to increased costs and less profit. Also sometimes the company cant achieve planned daily production target due to some activity wastes, which not added value to the production process.These are not conducive to the company’s future development. In order to make the company more competitive, company must have a new strategy to solve these problems. To achieve and sustain manufacturing excellence, you have to eliminate waste across your global production …show more content…
Research Methodology I designed this study using a positivistic case study research methodology. A positivistic case study is distinguished from an interpretive case study by the development of a theory prior to data collection. The prior development of theory guides the design, collection, and analysis of data. 3.2.Data Collection Method Due to high costs, staffing, and engineering concerns, production lines cannot be stopped. The time available to collect data and an assembler’s ability to leave the production area for data collection activities is often very limited. The effectiveness and efficiency of the data collection methods I selected and the time required to collect data were critical factors in the design of this research study. 3.3. Data Assessment Methods Data was gathered using several methods which included questionnaires, interviews, sociograms, and observation. Questionnaire. Data from the Relational Coordination Questionnaire was analyzed using a 4-point Likert
Production practices have had an important role in satisfying the dynamic market. Many approaches have being developed in order to respond effectively to specific business requirements. In fact, some areas of management have focused its study on the overseeing, designing, and controlling the process of production in an effort to find the best methodology that ensures the business success and performance. However, complexities arise in this field because many variables such as costs, inventory, scheduling, suppliers, etc have to be considered in any business. Lean approach and the traditional approach are two points of view that aim to address this complexities, and those will be examined in this essay.
Abstract: To sustain the competition and remain alive in market the enterprises must implement the practices of Lean manufacturing techniques. The implementation of Lean producing enhances productivity of plant at the same time reducing scrap within the processes. In small scale process industry the major problem is of In-process inventory which increased the overall cost. In this paper such In-process inventory problem is analyzed by Break Even Analysis Method. Finally, the qualitative approach was used to decide most effective tool and Major potential benefits of Lean Manufacturing Techniques.
Defining a case study method indicates the problem and entails choosing/finding a solution to solve it. However, to answer research questions it is vital to demonstrate deep consideration of the elements related to particular research design, as well as to show the ability to reflect upon research philosophy and approach to theory (Easterby-Smith et al., 2012; Eisendhardt, 1989).
Case study research can be defined as a pragmatic method that works to understand the meaning of lived experiences, events, and interactions for people in particular situations through real-life context (Morese & Richards, 2003). The case study approach can be used for the in-depth investigation of an issue or life event. Case studies can uncover beliefs, attitudes and perspectives of those involved. In this case both teachers and students. The ultimate goal of a case study is to illustrate the complexities
Lean manufacturing is the production of goods using less of everything than in mass production: less human effort, less manufacturing space, less investment tools and less engineering time to develop a new product. A company becomes lean by continuously increasing its capacity to produce high-quality goods while
We as researchers may try to think about the causes and effects of the outcome of a certain behavior. How can we find out the exact cause of the behavior? It isn’t easy-which makes it a disadvantage of using case studies as a research approach.
Lean is defines the manufacturing philosophy that reduces the time between the shipping and customer demand, which based on the systematic method by eliminating waste, that means giving the customer what they want when they want it, and don 't waste whatever. Rahmana, Sharif and Esa (2013) suggested lean production is mentioned to improve the company 's performance from the philosophy in reducing waste in order. That means, lean system destination is the decrease cost by removing the non-value activities, which they are applying a category of tools and techniques for checking and eliminating defective in the production process. In the Evenort Company should emulate the five overriding principles of lean thinking in terms of implementing lean that there is guarantee the company has been driving correctly in the lean manufacturing (Cardiff 2015) as can show in table 1.
This literature review aims to achieve insight into lean manufacturing and how it can be applied within a production environment. In today’s global market, it is important for maker withstand to remain competitive in their market and to understand the principles of lean manufacturing and the step tp implement them to ensure that they are on the leading edge of manufacturing. This literature review describes the lean concepts that are used in this project.
Lean production of vehicles was started in Japan by Toyota company. It has some similarities with the mass production; however, it is quite different from the craft production. One of the main similarities that the lean production shares with the mass production is that they both use the assembly line for the production of the vehicles, which was initiated by Ford. Unlike, mass production: “Ohno placed a cord above every work station and instructed worker to stop the whole assembly line immediately if a problem emerged that they couldn’t fix” (56). In the mass production, if the problem occurred, and no one paid attention to it while the production process, then the car company had to fix the errors in all the vehicles that had been produced no matter how large the quantity was. In the lean production of vehicles: “Ohno instead instituted a system of problem-solving called “the five why’s” (56). Taiichi Ohno, the founder of Toyota company, made sure that once the problem has been identified in the production process, then what kind of precautions company can take to prevent the problem, so it never occurs again, which saved a lot of time compared to mass production. One similarity that lean production has with the craft production is that the vehicles were not produced on a larger scale, rather they were diverse small vehicles, such as trucks and cars. In the mass production, changing the die cut process took months; however, in the lean production process reduced
Generally, there are four strategic approaches for case study analysis as identified by (Yin, 2014), namely, theoretical proposition reliance, ground up data strategy, descriptive and plausible rival explanation. Theoretical proposition strategy conforms to the idea of data been analysed based on the theoretical position of the research and study objectives (Gray, 2014; Yin, 2014). On the other hand, different analytical methods can be combine with analytical strategies in qualitative studies analysis such as pattern matching, time series analysis and thematically analysis (Braun & Clarke, 2006; Yin, 2014). Due to the nature of this study, thematic analysis technique is employed. Thematic analysis is a technique
The greatest challenges to any manufacturer in implementing a lean manufacturing strategy is attacking those processes that cause one of the seven types of waste first, and second, creating a more synchronized manufacturing strategy. The major characteristics of this strategy are
The Industry of Industries in Transition. they look through the history of the automobile manufacturing by spelling out Henry Ford and Alfred Sloan, who left behind the old-fashioned type of production, craft production, and began a new age of the world manufacture with mass production. Also, they mention about Eiji Toyoda and Taiichi Ohno, who initially started the conception, “lean production”, which, nowadays, has been seeking by manufacturers of all kinds of industries on over the world. In addition, the writers provide a quick view in the comparison among craft production, mass production, and lean production in which they point out the drawbacks of craft production, the obstacles of mass production, and the advantages of lean production. The authors emphasize that no lean manufacturer has ever reached the ideal target of lean production, but they will continuously attempt to gain the perfections of lean production. This section, additionally, represents the impact of lean production on the professional careers and the working conditions of
Operations and supply chain management is a concept that has flourished in domains such as manufacturing and express industry by offering a methodology to solve and relieve waste problems. There are two main approaches in operations and supply chain management: lean approach and conventional approach. In this assignment, I will compare the two approaches by summarizing their characteristics and analyzing the strengths and weaknesses of each approach. Finally, I will discuss the key problems faced by transitioning from conventional to lean approach.
The Industry of Industries in Transition. they look through the history of the automobile manufacturing by spelling out Henry Ford and Alfred Sloan, who left behind the old-fashioned type of production, craft production, and began a new age of the world manufacture with mass production. Also, they mention about Eiji Toyoda and Taiichi Ohno, who initially started the conception, “lean production”, which, nowadays, has been seeking by manufacturers of all kind of industries on over the world. In addition, the writers provide a quick view in the comparison among craft production, mass production, and lean production in which they point out the drawbacks of craft production, the obstacles of mass production, and the advantages of lean production. The author emphasize that no lean manufacturer has ever reached the ideal target of lean production, but they will continuously attempt to gain the perfections of lean production. This section, additionally, represents the impact of lean production on the professional careers and the working condition of employees these days. In the end of this
EijiToyado post World War II aimed to augment Toyota worldwide. According to him the manufacturing systems in America would not satisfy his goals. He established Toyota Production System to achieve good quality, flexible output while reducing waste.In today’s world Toyota Production System is known as ‘Lean Production’, a more improved theory and was first made known through The machine thatchanged the world (Womack et al., 1990). ‘Lean projects’ are project’s that delivers a maximum value while creating minimum waste.Lean production includes teams of worker who are multi skilled and are present at all stages in addition use machines that are highly automated to