Reducing production wastes at continuous process using lean manufacturing concept

Nazman, Nurul Afidah (2021) Reducing production wastes at continuous process using lean manufacturing concept. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Lean is an approach for eliminating waste without losing efficiency in a production process. The client describes value with regard to how much they are willing to spend for the particular product. Via Lean Manufacturing concept, value added products or activities turn out to be clear by extracting or minimising things that does not add value. The purpose of this project is to reduce production wastes at continuous process using Lean Manufacturing concept. The two objectives of this project are; (i) to analyses the effectiveness of current solution for waiting, rework, motion, and transportation wastes at production line, and (ii) to propose solutions for improving the effectiveness of on-line packing using appropriate Lean Manufacturing tools and techniques. All data that obtained through observation and 5W+1H are collected from Stripping Line 112 in order to clarify possible root causes of unachieved Key Performance Indicator (KPI), which is targeted at 90 carton per hour of production rate. The root causes were identified using Ishikawa Diagram and further analysed with 5Why analysis. The main root cause is nature of off-line packing, as solution has been provided for the root cause of production run based on production order. From a thorough analysis of root cause, the application of on-line packing is proven to be effective as it eliminates all the undesirable wastes and non-value-added activities in the nature of off-line packing. Two main solutions have been proposed as improvement to current on-line packing system that are; (i) Simplifying auto layer display to combat rework waste with development of Standard Operating Procedure (SOP), and (ii) Implementation of powered roller conveyor in reducing material handling issue with development of SOP. In conclusion, the proposed solutions will be able to achieve the KPI at Stripping process as it has been well justified based on success stories in related literatures.

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