Production Improvement Steps: Lean, Six Sigma and Lean Automation
Article Sidebar
Main Article Content
Abstract
With the effort of cost reduction, manufacturers attempted to be more automated. Some of them brought automated equipment, such as robot arm, into production line but were unable to gain successful implementation causing loss due to unused machine. The research is aimed to develop improvement steps based on activities of lean manufacturing that brings continuous and productive production line. Six sigma activity with statistical application brings production line to be less variability and more control enough for lean automation activity. The last activity requires smooth operations of production control, equipment maintenance and raw materials. The 15-steps assure for the projects that follow will be successful. A case study is implemented on three production processes, stamping, forming and piercing. Its result is the transformation into lean semi-automation processes that cycle time is reduced by 55.1% and overall equipment effectiveness index is increased by 15.2%.
Article Details
References
Antony, J., Suder, V.M., Sreedharan, R., Chakraborty, A. & Gunasekaran, A. (2019). A systematic review of lean in healthcare: a global prospective. International Journal of Quality & Reliability Management, 36, 1370-1391.
Dadashnejad, A. & Valmohammadi, C. (2019). Investigating the effect of value stream mapping on overall equipment effectiveness: a case study. Total Quality Management & Business Excellence, 30, 466-482.
Dennis, P. (2015). Lean production simplified (3rd ed.). CRC Press.
Department of Industrial Promotion and Denso International Asia. (2019). Primary Course of Lean Automation System Integrators (LASI). Industrial Promotion Center Region 9.
Hakimi, S. Zahraee, S.M. & Rohani, J.M. (2018). Application of Six-Sigma DMAIC methodology in plain yogurt production process. International Journal of Lean Six Sigma, 9, 562-578.
Issarapong, N., Taengphukieo, R., To-on, P., Chareatratchai, U. & Khumla, P. (2019). Production time reduction using lean manufacturing concepts: a case study of radial tire manufacturing. Apheit Journals, 1, 76-90.
Kolberg, D. & Zuhlke, D. (2015). Lean automation enabled by industry 4.0 technologies. IFAC-PapersOnline, 1870-1875.
Kumar, S., Kumar, A. & Singh, B. (2018). Process improvement through Lean-Kaizen using value stream map: a cause study in India. The International Journal of Advanced Manufacturing Technology, 96, 2687-2698.
LASI Trainers. (2020). LASI SI Designer (Warrior) Training, Gen. 5. Thai-German Institute (Bangkok center), Kloawnamtai.
Lawton, T. (2007). Implementing automation after making lean improvements. https://ui.customsearch.ai/hosted?q=implement%20atuomation&customCoNfig=4165927293&market=en-us&safesearch=moderate.
Montgomery, D. C. (2013). Introduction to statistical quality control (7th ed.). John Wiley & Sons.
Nafais, S. (2017). Automated lean manufacturing. https://www.researchgate.net/publication/317042141_Automated_Lean_Manufacturing
Nihlah, Z. & Immawan, T. (2018). Lean manufacturing: waste reduction using value stream mapping.
Proceedings of the 3rd international conference on energy, environmental, and information system held in Semarang 14-15 August 2018 (pp. 1-6). Indonesia.
Park, S.H., Shin, W.S., Park, Y.H. & Lee, Y. (2017). Building a new culture for quality management in the era of the fourth industrial revolution. Total Quality Management & Business Excellence, 28, 934-945.
Saraswat, P., Kumar, D. & Sain, K.S. (2015). Reduction of work in process inventory and production lead time in a bearing industry using value stream mapping tool. International Journal of Managing Value and Supply Chains, 6, 27-35.
Sony Corporation. (2000). Sony Six Sigma Trainer Course. Sony Corporation.
Sony, M. (2018). Industry 4.0 and lean management: a proposed integration model and research propositions. Production & Manufacturing Research, 6, 416-432.
Thanachotanankul, P., Siripanya, A., Panyakunanont, P. & Tantiphanwadi, P. (2020). LASI SI Designer (Warrior), Gen. 5, Group 1’s Paper. Thai-German Institute (Bangkok center), Kloawnamtai.
Yamazaki, Y., Takata, S., Onari, H., Kojima, F & Kato, S. (2016). Lean automation system responding to the changing market. Proceedings of the 49th CIRP conference on manufacturing systems held in Stuttgart 25-27 May 2016, (pp. 201-206). Germany.