Karthik Bharathi S., S. Vinodh, Sriharsha Devarapu and Goutham Siddhamshetty
The purpose of the study reported in the paper is to apply a structured problem-solving approach based on the Lean approach to analyse weld defects and derive appropriate…
Abstract
Purpose
The purpose of the study reported in the paper is to apply a structured problem-solving approach based on the Lean approach to analyse weld defects and derive appropriate solutions.
Design/methodology/approach
Manufacturing organisations involved in welding fabrication are expected to reduce weld defects to attain competitive advantage. Weld defects need to be systematically analysed for valve performance enhancement. In this research study, Lean approach is used to reduce variations and waste by annihilating the root causes for failures that occur during submerged arc welding (SAW) process.
Findings
The deployment of solutions facilitated weld defect reduction and substantial financial savings for the organisation.
Research limitations/implications
The framework has been test-implemented for analysing variations and wastes generated in the SAW process. In future, studies could be conducted for assessing different welding processes.
Practical implications
The proposed Lean framework has been successfully implemented in a large-scale manufacturing unit involved in fabrication work.
Originality/value
Lean framework has been test-implemented in a large-scale manufacturing organisation involved in weld fabrication work.
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Nilda Tri Putri and Lora Seprima Dona
The purpose of this paper is to redesign the layout of production floor by considering lean manufacturing in order to eliminate the waste and using Block Layout Overview with…
Abstract
Purpose
The purpose of this paper is to redesign the layout of production floor by considering lean manufacturing in order to eliminate the waste and using Block Layout Overview with Layout Planning (BLOCPLAN) algorithm to attain new layout of facilities in Indonesian home-food industry.
Design/methodology/approach
The common problems that might be appearing in home-food industry, especially in the developing countries like Indonesia are unstandardized production process and unorganized work environment which could produce the waste. One of many solutions to handle this problem is improving the work area (work station) in production floor by rearranging and designing standard operating procedure (SOP) by using lean manufacturing concept. The initial data to minimize the waste is motion time study (data) to identify production standard time. The next step is identifying the common waste(s). Meanwhile, the production floor layout used in this research is designed by using BLOCPLAN algorithm.
Findings
The recommendation of shop floor facility layout is based on identified waste, which is excess transportation. Subsequently, standard operational procedure (SOP) is developed to support the recommended facility layout as the reference for cookie production process so it can minimize the waste.
Research limitations/implications
Lean concept is one of method that is widely implemented to reduce the occurrence of defective products and waste that do not provide added value. Based on previous researches, it was found that the concept of lean manufacturing can be applied in various types of service and manufacturing industries, both large companies and small and medium enterprises. Home-food industry competition nowadays is getting intense. This condition makes the stakeholders (of home-food industry, especially in Indonesia) need high performance and productivity to keep their business stable in winning the competition. The new layout can reduce the disadvantages of actual condition.
Practical implications
This research is useful for small- and medium-sized enterprises (SMEs) in Indonesia especially for home-food industry. The BLOCPLAN layout (as the recommendation) has displacement moment with reduction of 40 percent.
Social implications
This research believed that it can help SMEs improve their productivity in producing cake and cookies in terms of better layout which can reduce worker movement and standardized working procedure. The design of the production facility layout is a method used to rearrange the production process area so that the distance between processes can be minimized. SOPs was provided as the direction and supervision of workers to work according to standards.
Originality/value
SOP design can support recommended layout as the reference on making the cake (product) to eliminate wastes, which are motion/movement (alternating in production process flow) and long waiting time due to process delays.
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Sufyan Sikander, Afshan Naseem, Asjad Shahzad, Muhammad Jawad Akhtar and Ali Salman
In recent years, especially after the COVID-19 pandemic, home textile production orders decreased significantly. This sudden drop in production has increased industry competition…
Abstract
Purpose
In recent years, especially after the COVID-19 pandemic, home textile production orders decreased significantly. This sudden drop in production has increased industry competition, making customer satisfaction more challenging. As a result, it has become imperative for the industry to deftly navigate such ongoing challenges.
Design/methodology/approach
This study examines textile production efficiency methodically. Customer requirements like quality, on-time delivery, better working conditions, cost-effectiveness and facility safety audits are understood first. Quality function deployment (QFD) turns client requirements into technical requirements. Prioritise and analyse risks using Monte Carlo simulation and Pareto charts. Consequently, experts and literature propose corrective measures, which are tested in a pilot run to see how they affect production.
Findings
QFD, define, measure, analyse, improve and control (DMAIC) and Monte Carlo simulation were used to reduce high-priority risks and meet client requirements in this study. The house of quality helped relate customers’ requirements and technical requirements. Monte Carlo simulation has also improved risk prioritisation by providing a flexible mathematical structure for identifying and managing the most important risks.
Originality/value
This study is novel in the way it applies this integrated approach to the understudied home textile sector. Unlike traditional DMAIC, this study introduces a novel matrix encompassing all defects. This study offers a data-driven approach to improve product quality, meet customer expectations and reduce prioritised risks in home textile manufacturing.
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Nandkumar Mishra and Santosh B. Rane
The purpose of this technical paper is to explore the application of analytics and Six Sigma in the manufacturing processes for iron foundries. This study aims to establish a…
Abstract
Purpose
The purpose of this technical paper is to explore the application of analytics and Six Sigma in the manufacturing processes for iron foundries. This study aims to establish a causal relationship between chemical composition and the quality of the iron casting to achieve the global benchmark quality level.
Design/methodology/approach
The case study-based exploratory research design is used in this study. The problem discovery is done through the literature survey and Delphi method-based expert opinions. The prediction model is built and deployed in 11 cases to validate the research hypothesis. The analytics helps in achieving the statistically significant business goals. The design includes Six Sigma DMAIC (Define – Measure – Analyze – Improve and Control) approach, benchmarking, historical data analysis, literature survey and experiments for the data collection. The data analysis is done through stratification and process capability analysis. The logistic regression-based analytics helps in prediction model building and simulations.
Findings
The application of prediction model helped in quick root cause analysis and reduction of rejection by over 99 per cent saving over INR6.6m per year. This has also enhanced the reliability of the production line and supply chain with on-time delivery of 99.78 per cent, which earlier was 80 per cent. The analytics with Six Sigma DMAIC approach can quickly and easily be applied in manufacturing domain as well.
Research limitations implications
The limitation of the present analytics model is that it provides the point estimates. The model can further be enhanced incorporating range estimates through Monte Carlo simulation.
Practical implications
The increasing use of prediction model in the near future is likely to enhance predictability and efficiencies of the various manufacturing process with sensors and Internet of Things.
Originality/value
The researchers have used design of experiments, artificial neural network and the technical simulations to optimise either chemical composition or mould properties or melt shop parameters. However, this work is based on comprehensive historical data-based analytics. It considers multiple human and temporal factors, sand and mould properties and melt shop parameters along with their relative weight, which is unique. The prediction model is useful to the practitioners for parameter simulation and quality enhancements. The researchers can use similar analytics models with structured Six Sigma DMAIC approach in other manufacturing processes for the simulation and optimisations.