Lean manufacturing implementation for the reduction of production times and quality issues in industry

Mahyuddin, Nurhanisah (2021) Lean manufacturing implementation for the reduction of production times and quality issues in industry. Project Report. Universiti Teknikal Malaysia Melaka, Melaka, Malaysia. (Submitted)

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Abstract

This study has been carried out at a chicken production process factory to identify the source of problem that caused production delays and quality issues in the industry. This study has conducted a direct time study to identify the time spent for each process and a Current Stream Map (CSM) was developed to show the flows of the process in current production plant. The non-value-added activities have been identified using Ishikawa diagram and Failure Modes and Effects Analysis (FMEA) in each element of the process and five types of waste has been found which are waiting, motion, transportation, defects, and inventory waste. As there are no proper equipment for slaughtering process and handling machine wrongly in chicken production process factory increased the production time and led to quality issues. An improvement plan which consists of Automatic Poultry Hanger, 5S pillars, new facility layout and Standard Operating Procedure (SOP) has been proposed to the industry to reduce the waste, improve the current production method, and remove the unnecessary elements. A Future State Map (FSM) of the revised time utilization of the process were developed which shows an improvement of time utilization by 21%.

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