Elimination of product shortage at dispatch line in manufacturing industry by using lean tool

Azman, Nor Azatul Fasya (2017) Elimination of product shortage at dispatch line in manufacturing industry by using lean tool. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

The first implementation of Kaizen was done by Toyota in its production process. Kaizen is a common practice in Japan and also applies to processes in the manufacturing industry with their aims for improvements in productivity, effectiveness, safety and waste reduction. The benefits of applying the Kaizen approach are improved problem solving, improved competitiveness and improved customer satisfaction by coming from higher quality products with fewer faults. While the success of a manufacturing organization depends on how the customer is satisfied with the products and the goal is to satisfy the customer need with the exact product, quality and quantity. The purpose of this study is to improve product shortage at Dispatch Line of manufacturing industry by using Lean Manufacturing Tools. Product shortage was studied by using Voice of Customer (VoC) data and several analysis tools to find the root cause of this problem. Based on this study, customer with the highest complaint is identified. Improvements only focuses on this customer and Kaizen was implemented to eliminate the issue of product shortage. Standard work is implemented to overcome the lack of procedure at Dispatch Line and to standardize the proper method. This standard work is referred to Work Instruction (WI) for palletizing process. The improvements decrease the number of customer complaints by about 67% for a three months period. This result shows that Kaizen implementation in manufacturing industry is efficient in achieving customer satisfaction by eliminating product shortage.

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