International Journal of
Engineering Science and Futuristic Technology A Peer-reviewed journal ISSN : 2454-1338(O), ISSN : 2454-1125(P) IJESFT 70 (2020) 001-010
Workstation Optimization By Applying Lean Manufacturing Technique-A Production Case Study Muhammad Sadeque¹,*, Viwek Vaidya² 1
Mechanical Engineer, HCL America Inc, Sunnyvale, CA, United States
2
Professor, Concordia University, Canada ABSTRACT:
This paper proposal was to ‘Optimize workstation by applying lean’ by finding the possible causes, waste and non-value-added activities in workplace. Lean helps industry to eliminate waste. For example, most of the welding shops assume welder works 8 hours in a shift but at the end of day measuring welding arc duty cycle may show a less satisfactory number. This can impact negatively the entire production system. As we know, ‘Robotic welding - duty cycle is programmed between 80% -95% depending on shop nature and work environment. Robotic operation is expensive including initial setup to production. Most of the welding shops use manual or semiautomatic welding processes such as GMAW, FCAW, SMAW, SAW or TIG welding. Research shows that by using manual MIG or GMAW welding, only 16% duty cycle can be achieved. Applying lean in welding, duty cycle can be increased from 16% to 35%. We took a real case in Canada where the industry called” XYG” (Company name hidden due to confidentiality) had low performance of the production system. We measured the factors that were involved for low performance including welding technique and tried to optimize the production system by applying Lean.
© 2020 A D Publication. All rights reserved
Keywords: 1.
Value Stream mapping, Kanban, Lead time, Cycle time
Introduction
Lean manufacturing method is to improve business and manufacturing processes and drive profitability for the companies. Lean manufacturing are proven concepts that can save companies billions of dollars. Focusing on eliminating the wastes and is based on the philosophy of getting all levels of an organization involved. It was developed by Toyota in the late 1950’s. Many people are familiar with the term ‘Lean manufacturing’ and ‘Six Sigma’, but sometimes do not understand properly which one is good fit for them. Six Sigma works on the principle that reducing variation gets to the root of any problem. People argue it has technically superior way of working. On the other hand, Lean Manufacturing uses basic improvements to make business, processes more effective. The essence of lean thinking is grounded in the Toyota Production System (TPS), which considers people and processes to be the two main pillars of any business.
* muhammad.sadeque@hcl.com
ID: IJESFT2020V06I10380463
Journal access: www.adpublication.org © 2020 A D Publication. All rights reserved Volume 6 Issue 10, 2020