Lean Tools Application For Productivity Improvement

Mohd Fuzi, Muhammad Zahid (2019) Lean Tools Application For Productivity Improvement. Project Report. UTeM, Melaka, Malaysia. (Submitted)

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Abstract

Line balancing is the common application to balance the processes in manufacturing industry. This application is a way to balance the workloads of the operator. Time study is performed at the workstation in a production line. Workstation is the physical location in a production line. However, to balance the workload and task equally is the difficult issue for the production management team. The unbalanced task and workload will cause the numbers of productivity decrease. The standard of work must be completed according to takt time and each station must have a designated location. This study was conducted at Production Line 2 (P2) in Ain Medicare Sdn. Bhd. This study covered at unloading room of P2 that consist of four stations. The additional movement in product transferring will affected the cycle time of the station due to inappropriate workstation design. In observation process, the method of time study is being used to identify the takt time, cycle time, output, lead time and demand. In order to reduce the cycle time, non-value added activities will be identify by Yamazumi chart and Ishikawa diagram. Based on data analysis, an improvement idea had been proposed to eliminate non-value added activities. The comparison between before and after improvement had been made by simulation software which is Witness Horizon. Thus, the productivity increased from 0.33 to 0.44 after the implementation of improvement idea.

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