Productivity improvement of sub-assembly process in casting industry using lean manufacturing tool

Aznam, Aiman Syafiq (2021) Productivity improvement of sub-assembly process in casting industry using lean manufacturing tool. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Quality with quantity is the key element that helps the company remain in competition with others. Technology continues to rise day by day and this indirectly contributes to client demands rising. Lean manufacturing can help to reduce the costs, waste, waiting time, defect and improve product delivery speed. This project seeks to analyse the product flow in an assembly line of Dormakaba Production Malaysia Sdn Bhd, located in Cheng, Melaka. The problem statement in this is for management to establish a visualized tool for the new process of casting industry which is sub assembly process. The sub-assembly process is a new process in Dormakaba Production Malaysia Sdn Bhd and therefore lean manufacturing need to be apply to improve the productivity for their product realization. There is no links production control and scheduling functions such as production planning and demand forecasting to production scheduling using operating parameters for the manufacturing system which determines the production rate. The main objectives of this project are to investigate the current process of each model in sub-assembly department based on the product family matrix, to identify the model that need to carry out lean tools to reduce the cost, waste, waiting time, defect and product delivery speed and to develop the Value Stream Mapping (VSM) for selected model. The total station name/model such as SAS, MSB, Piston and Bearing is analysed based on the number process, quota per shift, gross weight (kg) and man power in sub-assembly department for past 9 month. The problem such as inefficient Standard Work sheet and bottleneck of process was analysed. The Future VSM was created, the map of work area is restructured and the design of base plate supporting tool is created to reduce the cycle time and waiting time. This implementation of lean manufacturing tool increased the productivity improvement of sub-assembly process in Dormakaba Production Malaysia Sdn Bhd.

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