Implementation of Lean Manufacturing System in Bogie Assembly in Railway Coach Factory
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Abstract:
Elimination of the non-value added activities in the bogie assembly shop during bogie assembly process. The various non-value added activities are found in the assembly shop such as excess distance between each assembly stages, excess cost to flow of material from one stage to another stage, waste of time and non-flexibility of shop. These types of non-value added activities occur due to the improper arrangement of bogie assembly stages. Implementation of lean manufacturing systems through layout design by the conversion of existing layout of bogie assembly shop into proposed layout. Analysing the existing layout by using the CRAFT method to find out the best optimized layout .Interchanges are made between each stages that help to correct the present layout. Design calculation are done for various stages .Interchanging of stages of different section are considered by distant matrix and total cost calculations .Various cost of all the pair wise interchanged stages are estimated to find the best low cost interchange. As per the design calculation best interchange between the two stages are considered and that lead to the development of new proposed layout in which all the non-value added activities are eliminatedKeywords:
Bogie
Factory (object-oriented programming)
Product and factory development: product development product design factory requirements factory design human elements in the factory computers and controllers. Factory operations: practical cost estimating for manufacturing product tooling and equipment computer-aided process planning work measurement control of production and materials control of quality. Parts fabrication: principles of structural mechanics materials characteristics of metals conventional fabrication
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Product engineering
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Lean Manufacturing principles were introduced in an existing Gallium Arsenide IC factory which manufactures state-of-the-art RF products. While the products produced in this factory were of cutting-edge performance and design, much of the equipment and factory procedures were vintage and in some cases outdated. This situation had worked well at modest production volumes; however, ramping to high-volume production has proven difficult. After introducing a new production framework based on Lean Manufacturing principles, dramatic improvements have been achieved in all aspects of factory performance. We will describe the implementation strategy, discuss some of the roadblocks that had to be eliminated, and give a summary of the improvements which were achieved.
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This paper documents the basic manufacturing philosophies and methodologies utilized for the design and implementation of a Lean Manufacturing remanufacture cell. Remanufacture deals with overhauling or reworking products that have been in service and need modification in order to continue to be serviceable. This remanufacturing cell implementation is the first cell of an eighteen-cell manufacturing and remanufacturing system. A systematic detailed case study is utilized as a Lean Production example and proves the flexibility of Lean Manufacturing to be adaptive while being cost effective in the remanufacture arena. This study provides key insights into a concept and strategy for implementing Lean Production thinking — cellular manufacturing. Most factories need significant assistance in understanding how to make Lean Production work; this paper provides many insights into both the theory and application of cellular manufacturing/assembly systems for remanufacture.
Remanufacturing
Cellular manufacturing
Lean laboratory
Lean software development
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Both literature and manufacturing companies state that simulators for providing training in lean production to industrial employees must be similar to the work environment. This motivated the design of Karlstad Lean Factory, which is a training environment that realistically resembles an industrial environment. It is a full-scale training facility that incorporates a combination of materials processing and assembly. Parameters such as processing times, breakdown intervals and repair types can be set. Examples of basic and more advanced training scenarios are given. Experiences from training groups of industrial employees are described; inhomogeneity of these groups requires some specific attention.
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Abstract The paper deals with the use of Lean Manufacturing tools in improving the production process of car arm rests in a car manufacturing company in Poland. The article describes the original condition of a single production process of assembling ready pieces to produce car arm rests. The original condition was assessed and described with the use of some basic Lean indicators and value stream mapping. The aforementioned tools allowed to assess the process condition and to identify the organizational issues and their sources. It also enabled to reorganize the process and increase its efficiency. The further part of the article describes the results of improvement actions. The process assessment was held and improvements introduced in the first quarter of 2018.
Value stream mapping
Lean laboratory
Rest (music)
Toyota Production System
Manufacturing process
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The Toyota Production System (TPS) is an integrated socio-technical system, developed by Toyota that comprises its management philosophy and practices. The TPS organizes manufacturing and logistics for t he automobile manufacturer, including interaction with suppliers and customers. The system is a major precursor of the more generic “Lean manufacturing.”
Toyota Production System
Lean laboratory
Manufacturing
Lean software development
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Abstract The concept of Lean Manufacturing (or Lean Production) is widely present in the quality management systems of the best factories. Foundry plants in Poland have continuously been implementing modern management tools; however, the experiences of the authors show that the usage of lean tools is at a lower level in domestic foundries than in similar plants abroad. This was the reason why a survey was prepared and over 300 foundry plants were questioned regarding the application of Lean Manufacturing tools. The questions (20 in total) asked if and what tools are implemented in the plant and what benefits have been achieved, or why lean tools have not been implemented in a particular plant. The answers were thoroughly analysed and the results show that, among others, only 29% of all foundries use lean tools, and the main reason why most of them do not is that these tools are not understood well enough.
Foundry
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Total Quality Management
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This paper analyzed the current problems of production system in automobile manufacturing industry,elaborated the important characteristics of the idea of lean production,and pointed out the importance of applying the idea in the automobile manufacturing industry.At the same time,some concrete measures for carrying out the mode of lean production were introduced.
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The principle of lean manufacturing has been successfully implemented in a number of industries, including electronics and automotive. This is not the case for other industries, such as the sewing industry, and this research focuses on implementation of lean manufacturing techniques in the sewing industry. One specific sewing line in a sewing plant was selected as a case study, and sewing process characteristics are identified. Five types of waste are identified and analyzed in the sewing line with the aid of value stream mapping: defects, inventory, overproduction, transportation, and waiting time. Applied lean manufacturing techniques include line balancing, layout redesign, and quality at the source. Impacts of implemented lean techniques on production are analyzed, and an improved future-state value stream map is developed. Results show approximately 96% reduction in production wastes in addition to 43% reduction in lead time.
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Lean laboratory
Line (geometry)
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The paper describes the core idea of Lean production as a methodology with series of tools for continuous improvement in the electronics manufacturing. The main idea is to show the electronics production increasing profitability based on scientific labor management and demonstrating the advantages of their usage for workers in operation. Main optimization parameters for production line were chosen and analyzed with regard to the specifics of automotive electronics production. The paper provides an implementation of step-by-step line optimization procedure using main Lean tools. One of the biggest automotive electronics suppliers in the world was under observation and Lean production optimization was considered on one of the production lines. Paper sums up the matters deserving attention in the Lean production implementation course to provide experience for companies working in electronics production and who are going to apply Lean production in the future.
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