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Lean Management: Assignment 1 Analysis of Leam Implenmentation Case Study

The document analyzes a case study of lean implementation at a Malaysian batch printing company. The company faced problems like low productivity and quality issues. To address this, the company implemented lean tools like TPM, one-piece flow, 5S, and OEE. Through TPM, availability increased to 70.83% and quality improved to 87.5%. One-piece flow reduced production time from 75 to 67.41 seconds per piece. 5S organized the workspace. Overall equipment effectiveness improved from 34.3% to 60%. The conclusion suggests adding quality control and control charts to further address defects.

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Nirmal
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34 views

Lean Management: Assignment 1 Analysis of Leam Implenmentation Case Study

The document analyzes a case study of lean implementation at a Malaysian batch printing company. The company faced problems like low productivity and quality issues. To address this, the company implemented lean tools like TPM, one-piece flow, 5S, and OEE. Through TPM, availability increased to 70.83% and quality improved to 87.5%. One-piece flow reduced production time from 75 to 67.41 seconds per piece. 5S organized the workspace. Overall equipment effectiveness improved from 34.3% to 60%. The conclusion suggests adding quality control and control charts to further address defects.

Uploaded by

Nirmal
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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LEAN MANAGEMENT

ASSIGNMENT 1
ANALYSIS OF LEAM IMPLENMENTATION CASE STUDY

BY:
NIRMAL K MANOJ
PRIYANKA R
YASHRAJ SINGH RATHORE
ANALYSIS OF THE CASE STUDY

Introduction
The company that involved in this study is a Malaysian Batch printing industry. There
are several problems faced by the industry which included low productivity, untidy
working environment that affect the effectiveness of process flow, lack of labelling for
tools, inventory that cause unwanted use of space, product defects, unnecessary motion
and lack of multi-skill workers. Therefore, the researcher aims to overcome the problem
faced by implementing lean.

Types of lean tools implemented

TPM, one-piece flow, 5S were the main lean tools implemented.

Total productive maintenance (TPM): It focused on solving problem for wastes that
related with production system.TPM makes sure there are no breakdowns, no small
stops or slow running, no defects, and no accidents. The TPM approach is mainly
orientated around employee empowerment, and encourages employees to take
ownership of their machinery, which in turn increases production uptime.TPM allocates
the job of maintenance workers to all plant workers. That way everyone is responsible
for machinery and equipment maintenance.
Overall Equipment Effectiveness (OEE): It was employed to measure the performance of
productive system. During factory visitation, data needed was collected via time
measurement for each working processes. This data was used further in calculating the
Overall Equipment Effectiveness (OEE) before and after lean implementation.

One piece flow: The industry was following the batch production system but now the
one piece flow was implemented as part of lean. One-piece flow layout was designed
using Flexsim software. The purpose of implementing one-piece flow is to reduce the
unnecessary transportation time, unnecessary process, waiting time, queue time and
total distance moved by operators can be reduced.

5S: One of the major problem faced by the industry was untidy environment. This was
improved by implementing the 5S lean tool. the 5S methodology helps a workplace
remove items that are no longer needed (sort), organize the items to optimize efficiency
and flow (straighten), clean the area in order to more easily identify problems (shine),
implement colour coding and labels to stay consistent with other areas (standardize)
and develop behaviours that keep the workplace organized over the long term (sustain).

Conclusion
Due to the implement of TPM, the availability rate for the machine reached 70.83%, the
Percentage of quality has been increase from 75% to 87.5% and the performance rate
was also increased from 78.57% to 82.35%. So, as a result overall equipment
effectiveness was improved from 34.3% to 60% through implementation of TPM.
Due to the change of production system from batch production to one-piece flow, the
time taken to produce one piece of garment was reduced to 67.41 seconds from 75
seconds (a difference of 7.59 seconds can be noticed). The target to be produced in an
hour was 50. So per hour 6.325 minutes was reduced. The total working days in a
month is 22 days. So in a month, a time of 5.80 hours was saved due to the
implementation of lean.

Suggestions

Due to the absent of quality control in production line, company get complaints from
customers about receiving defect products. Thus, it would help to have a work station
for quality control purpose.
Also controls charts can help in locating the defects. These charts have a central line
equating to the mean value and two other lines (upper limit line and lower limit line).
The values collected are plotted in the graph and they generally fall in the area inside
the upper and lower limit. The points outside this area are considered as defects and
can be identified easily and rectified.

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