Process Optimization Methods for Shop Floor Planning : A Study

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Process Optimization Methods for Shop Floor Planning : A Study

Varun Tripathi1

Department of Mechanical Engineering, Accurate Institute of Management & Technology, Greater Noida- (UP), India

GD Gautam2

Department of Mechanical Engineering, MIET, Greater Noida- (UP), India

Suvandan Saraswat3

Department of Mechanical Engineering, JSS Academy, Noida- (UP), India

Abstract Process optimization methods means regulation of production processes, and it must have done for shop floor improvement without changing any constraints. Process optimization is a quantitative technique for industrial decision making. So far whatever methods used for shop floor planning so far include mainly lean, kaizen, total quality management, and six sigma. These methods are used for maximizing productivity by the elimination of non-productive activities. The research work done so far, mostly focuses on the implementation of lean manufacturing as process optimization methods. The main aim of the present paper is to evaluate the present condition of process optimization methods used for shop floor planning. To do so, several articles were collected from journals which dealt with the implementation of process optimization methods. This study illustrates the present implementation level of process optimization methods in the worldwide industrial scenario and provides a unified theory for the implementation of process optimization methods.

Keywords- Process optimization methods; Lean manufacturing; Shop floor management; Waste elimination; Non-productive activities

  1. INTRODUCTION

    The main objectives of a production system such as maximizing throughput, minimizing costs, maximizing efficiency and maximizing workforce utilization can be achieved by the implementation of process optimization methods [1]. Process optimization methods are mostly evolved from the Toyota production system. These methods are used for improvement in productivity level by the elimination of non-value added activities. Lean manufacturing, kaizen, total quality management, and six sigma, are mostly implemented methods in industries because of a higher improvement rate in production [2]. In which, lean manufacturing is a prevalent method in present industries [3]. The main objective of the production system is to achieve high productivity with minimum utilization of resources and for this, lean manufacturing is a superior method [4]. Several articles demonstrate that most of the researches focus on finding out the source of wastes and suggest their views on implementing the lean method on the shop floor.

  2. OVERVIEW OF PROCESS OPTIMIZATION METHODS The major methods considered by the earlier articles for the implementation of the process optimization methods are Lean manufacturing, kaizen, total quality management, and six sigma. These methods improve each process required to transform the raw material into the final product through the observation of the process on the shop floor [5]. Lean eliminates non-productive activities [6]; Kaizen means continuously improvement in processes by involvement of overall employee of the shop floor [7]; Total quality management (TQM) is used for identification and elimination of non-productive activities, it improving the customer perception, and ensuring that workers must be upgraded with training [8]; Six Sigma is used for improvement in the quality of the product by identifying and eliminating the causes of defects [12]. The output of each process optimization methods is different, and implemented according to customer

    expectation and condition of the shop floor.

  3. PURPOSE AND METHODOLOGY

    The aim of present paper is to evaluate the implementation level of process optimization methods in industries and provides a unified theory for the implementation of process optimization methods. From several journals, the 180 papers were searched and in which found just 21 according to the objective. This significant reduction in the number of articles is because the process optimization methods are used in various areas like physics, chemistry, business, and economics, and the present article focuses on in the area of mechanical, mining, mining machinery, electrical, electronic, and automobile. The results obtained by the implementation of process optimization methods for shop floor planning as found in extensive review has been described by table 1.

    TABLE I. PROCESS OPTIMIZATION METHODS AND IMPROVED FACTOR OF PRODUCTION SYSTEM

    (IN TABLE, I MEANS IMPROVEMENT AND R MEANS REDUCTION)

    S.N.

    Authors

    Process optimization methods

    Improved factors

    Utilization of resources

    Working environment

    Quality

    Total time

    Total cost

    Productivity

    1.

    Alhuraish et al

    Lean manufacturing, six sigma

    I

    I

    I

    R

    R

    I

    2.

    Esa et al

    Lean manufacturing

    I

    R

    R

    I

    3.

    Rohani et al

    Lean manufacturing, Kaizen

    I

    R

    R

    I

    4.

    Mwanza et al

    Lean manufacturing

    R

    R

    I

    5.

    Choomlucksana et al.

    Lean manufacturing

    I

    I

    R

    R

    I

    6.

    Santos et al.

    Lean manufacturing

    I

    I

    I

    R

    R

    I

    7.

    AR et al.

    Lean manufacturing, Kaizen

    I

    R

    R

    I

    8.

    Salleh et al.

    Lean manufacturing, total quality management

    I

    R

    I

    9.

    Rahman et al

    Lean manufacturing

    R

    R

    10.

    Dotoli et al

    Lean manufacturing

    R

    R

    11.

    Gupta et al

    Lean manufacturing

    I

    I

    R

    R

    I

    12.

    Timans et al

    Lean manufacturing, six sigma

    R

    R

    I

    13.

    Ostlin et al

    Lean manufacturing

    I

    R

    R

    I

    14.

    Motwani

    Lean manufacturing

    R

    R

    15.

    Vinodh et al

    Lean manufacturing

    R

    R

    I

    16.

    Solding et al

    Lean manufacturing

    R

    R

    I

    17.

    Singh et al.

    Lean manufacturing

    I

    R

    R

    I

    18.

    Tripathi et al.

    Lean manufacturing

    I

    I

    I

    R

    R

    I

    19.

    Tripathi et al.

    Lean manufacturing

    I

    I

    I

    R

    R

    I

    20.

    Deshkar et al.

    Lean manufacturing

    R

    R

    I

    21.

    Masuti et al.

    Lean manufacturing

    I

    R

    R

    I

  4. RESULTS & DISCUSSION

    The implementation of process optimization methods for shop floor planning as found in the literature review shows that lean manufacturing is a prevalent method and mostly used by industries. The results obtained by lean manufacturing are superior in comparison to other methods, and lean manufacturing may have applicable in most cases. Figure 1 shows the implementation of process optimization methods. Figure 2 shows an analysis of industries where process optimization methods have implemented.

    Six

    work in process, transportation, waiting, time, cost, reworking, have the major aim of these methods. This improvement has been established perception that lean is a superior method in industries and may have applicable easily on the shop floor.

    REFERENCES

    1. I. Alhuraish, C. Robledo, and A. Kobi, The effective of lean manufacturing and six sigma implementation, Proc. 2015 Int. Conf. Ind. Eng. Syst. Manag. IEEE IESM 2015, no. October, pp. 453460, 2016.

    2. M. M. Esa, N. A. A. Rahman, and M. Jamaludin, Reducing High Setup Time in Assembly Line: A Case Study of Automotive Manufacturing Company in Malaysia, Procedia – Soc. Behav. Sci., vol. 211, pp. 215

      TQM

      4%

      Kaizen 7%

      sigma 8%

      Lean manufa cturing 81%

      220, 2015.

    3. J. M. Rohani and S. M. Zahraee, Production Line Analysis via Value Stream Mapping: A Lean Manufacturing Process of Color Industry, Procedia Manuf., vol. 2, no. October, pp. 610, 2015.

    4. B. G. Mwanza and C. Mbohwa, Design of a Total Productive Maintenance Model for Effective Implementation: Case Study of a Chemical Manufacturing Company, Procedia Manuf., vol. 4, no. Iess, pp. 461470, 2015.

    5. J. Choomlucksana, M. Ongsaranakorn, and P. Suksabai, Improving the Productivity of Sheet Metal Stamping Subassembly Area Using the Application of Lean Manufacturing Principles, Procedia Manuf., vol. 2, no. February, pp. 102107, 2015.

    6. Z. G. dos Santos, L. Vieira, and G. Balbinotti, Lean Manufacturing and Ergonomic Working Conditions in the Automotive Industry, Procedia Manuf., vol. 3, no. Ahfe, pp. 59475954, 2015.

    7. A. R. Rahani and M. Al-Ashraf, Production flow analysis through Value Stream Mapping: A lean manufacturing process case study,

      4

      4

      3

      3

      2

      2

      Fig. 1. Process optimization implementation

      6

      6

      6

      5

      4

      3

      2

      1

      0

      5

      6

      5

      4

      3

      2

      1

      0

      5

      Fig. 2. Description of industries

  5. CONCLUSIONS

There is extensive work has done on process optimization methods, which provides a wide perception for the implementation of a suitable method on the shop floor. Literature has proved that lean manufacturing has been broadly implemented method in industries. The higher level of improvement in results demonstrates that lean manufacturing is the most effective method in comparison to other process optimization methods. Process optimization methods represented through literature, and by these methods, different factors have been improved of the shop floor. The reduction of

Procedia Eng., vol. 41, no. Iris, pp. 17271734, 2012.

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  2. N. A. A. Rahman, S. M. Sharif, and M. M. Esa, Lean Manufacturing Case Study with Kanban System Implementation, Procedia Econ. Financ., vol. 7, no. Icebr, pp. 174180, 2013.

  3. M. Dotoli, N. Epicoco, M. Falagario, N. Costantino, and P. Bari, A Lean Warehousing Integrated Approach: A Case Study, 18th Conf. Emerg. Technol. Fact. Autom. (ETFA), 2013 IEEE, 2013.

  4. V. Gupta, P. Acharya, and M. Patwardhan, A strategic and operational approach to assess the lean performance in radial tyre manufacturing in India, Int. J. Product. Perform. Manag., vol. 62, no. 6, pp. 634651, 2013.

  5. W. Timans, J. Antony, K. Ahaus, and R. Van Solingen, Implementation of Lean Six Sigma in small- and medium-sized manufacturing enterprises in the Netherlands, J. Oper. Res. Soc., vol. 63, no. 3, pp. 339353, 2012.

  6. J. Östlin and H. Ekholm, Lean production principles in remanufacturing – A case study at a toner cartridge remanufacturer, IEEE Int. Symp. Electron. Environ., pp. 216221, 2007.

  7. J. Motwani, A business process change framework for examining lean manufacturing: a case study, Ind. Manag. Data Syst., vol. 103, no. 5, pp. 339346, 2003.

  8. S. Vinodh, K. R. Arvind, and M. Somanaathan, Application of value stream mapping in an Indian camshaft manufacturing organisation, J. Manuf. Technol. Manag., vol. 21, no. 7, pp. 888900, 2010.

  9. P. Solding and P. Gullander, Concepts for simulation based Value Stream Mapping, Winter Simul. Conf., pp. 22312237, 2009.

  10. B. Singh and S. K. Sharma, Value stream mapping as a versatile tool for lean implementation: an Indian case study of a manufacturing firm, Meas. Bus. Excell., vol. 13, no. 3, pp. 5868, 2009.

  11. E. Commission, L. L. P. Leonardo, and V. Transfer, Process optimization, pp. 145.

  12. Lean Yesterday , Today And Tomorrow.

  13. V. Tripathi, S. Sarswat. Lean Manufacturing for Shop Floor of Automotive Industries: A Study. Journal of Experimental & Applied Mechanics. 2018; 9(2): 5865p.

  14. Tripathi V, Saraswat S, " Lean management implementation in mining equipment manufacturing shop floor, " National Conference on Mining Equipment NewTechnologies, Challenges & Applications Dhanbad (India). 2018; 9-10 February: 710p.

  15. Masuti P. M., Dabade U.A., "Lean manufacturing implementation using value stream mapping at excavator manufacturing company", Materialstoday: proceeding, Volume 19, Part 2, 2019, Pages 606-610.

  16. A. Deshkar,S. Kamle, J. Giri, V. Korde, "Design and evaluation of a Lean Manufacturing framework using Value Stream Mapping (VSM) for a plastic bag manufacturing unit", Materialstoday: proceeding, Volume 5, Issue 2, Part 2, 2018, Pages 7668-7677.

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