Productivity Improvement Study Using Lean Techniques At Manufacturing Company

Joily, Sherilyn (2019) Productivity Improvement Study Using Lean Techniques At Manufacturing Company. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

Konica Minolta Sdn Bhd (M) is one of the manufacturing company located at Ayer Keroh, Melaka. This company is focusing on manufacture thirteen parts of printer then produce a full set of printers. The aim of this study is to apply the concepts of Value Stream Mapping (VSM) with the approaches of DMAIC tools then propose a Future State VSM in order to reduce the hidden waste occurs in a production line and to increase the productivity for the company. Furthermore, the problem statement indicated where the need to find out the hidden wastes that occurs in the manufacturing system and effect the productivity of the selected product. Next, the method used to solve the problem is by using VSM where it was the main tool used to identify the hidden waste occurs in the production line such as waiting waste, over-production waste, excessive inventory and motion waste in order to increase the productivity and output for the production line. An overview of this thesis is drafted by tittle selection, literature review, research methodology and did the company visit. First step before start with the VSM is to select product family, define the CVSM and developed the FVSM. Moreover, the results from this study clearly shows that the VSM brings out the positive impacts on the imbalance stage process even the result slightly improved from the CVSM. Moreover, lean tools and techniques such as Just-in-Time (JIT), Kaizen, and pull system helps to identify the waste and reduced it. As for the result, according to CVSM the value-added activities are 39.3% and the non-value-added activities is 60.65% and mostly cause by waste of waiting, over-production, excessive inventory and unnecessary motion from the operator in a process. The outcome for this study is the labour-hour productivity improved into 60% and the partial productivity increased to 67%. The new FVSM shows the new techniques proposed to the production line as the improvement that the waste has been reduced.

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