Waste identification in a pipe manufacturing industry through lean concept– A case study

Document Type: Research Paper

Authors

Department of Industrial and Production Engineering, Faculty of Engineering and Technology, Jessore University of Science and Technology, Jessore - 7408, Bangladesh.

Abstract

This study addresses the application of the lean manufacturing philosophy to the mass production sector with a focus on the plastic piping section of a selected plastic pipe manufacturing industry. In this study, the different weakness and waste of the piping section are measured by using the specific lean tools, such as Cause-effect diagram, Pareto analysis, Time Base Mapping, and 5S. The cause-effect analysis shows the various root causes of the waste time and rejection of the pipes. The Time Base Mapping measures the required time needed from the raw material to finish the product dispatch. The time has reduced approximately 17 hours by eliminating or reducing the non-value added work activities. The 5S analysis is done to focus on the effective workplace organization and standard work procedure. It also simplifies the work environment, reduces all possible waste and non-value added activity while improving quality, efficiency, and safety. In this study, we have found out the various types of waste (value-added activities and non-value added activities) exist in the piping section and the possible causes behind these activities that also have proposed some recommendation for the studied process industry in order to improve the performance of the piping section.

Keywords

Main Subjects


[1]     Womack, J. P., Jones, D. T., & Ross, D. (1990). The machine that changed the world. Rawson Associates, New York

[2]     Roriz, C., Nunes, E., & Sousa, S. (2017). Application of lean production principles and tools for quality improvement of production processes in a carton company. Procedia manufacturing11, 1069-1076.

[3]     Dhiravidamani, P., Ramkumar, A. S., Ponnambalam, S. G., & Subramanian, N. (2018). Implementation of lean manufacturing and lean audit system in an auto parts manufacturing industry–an industrial case study. International journal of computer integrated manufacturing31(6), 579-594.

[4]     Mostafaa, Sh., & Dumrak, J. (2015). Waste elimination for manufacturing sustainability, Procedia manufacturing, 2, 11–16.

[5]      Nallusamy, S., Adil Ahamed, M. A. (2017). Implementation of lean tools in an automotive industry for productivity enhancement-A case study. International journal of engineering research in Africa, 29, 175-185.

[6]      Hossen, J., Ahmad, N., & Ali, S. M. (2017). An application of Pareto analysis and cause-and-effect diagram (CED) to examine stoppage losses: a textile case from Bangladesh. The journal of the textile institute108(11), 2013-2020.

[7]     Vendan, S. P. & Sakthidhasan, K. (2010). Reduction of wastage in motor manufacturing industry. Jordan journal of mechanical and industrial engineering, 4(5), 579–590.

[8]      Syahputri, K., Sari, R. M., Tarigan, I. R., & Siregar, I. (2018). Application of lean six sigma to waste minimization in cigarette paper industry. IOP conference series: materials science and engineering. IOP Publishing.

[9]     Nallusamy, S. (2016). Productivity enhancement in a small scale manufacturing unit through proposed line balancing and cellular layout. International journal of perform ability engineering, 12(6), 523–534.

[10]  Obeidat, M. S., Al-Aomar, R., & Pei, Z. J. (2014). Lean manufacturing implementation in the sewing industry. Journal of enterprise transformation, 4(2), 151-171.

[11]  Dhiravidamani, P., Ramkumar, A. S., Ponnambalam, S. G., & Subramanian, N. (2018). Implementation of lean manufacturing and lean audit system in an auto parts manufacturing industry–an industrial case study. International journal of computer integrated manufacturing31(6), 579-594.

[12]  Joshi, A., & Kadam, P. (2014). An application of pareto analysis and cause effect diagram for minimization of defects in manual casting process. International journal of mechanical and production engineering, 2(2).

[13]   Islam, M. M., Khan, A. M., & Islam, M. M. (2013). Application of lean manufacturing to higher productivity in the apparel industry in Bangladesh. International journal of scientific & engineering research4(2), 1-10.

[14]  Garza-Reyes, J. A., Tangkeow, S., Kumar, V., & Nadeem, S. P. (2018). Lean manufacturing adoption in the transport and logistics sector of Thailand–An exploratory study. Proceedings of the international conference on industrial engineering and operations management Bandung, Indonesia (pp. 104-115). IEOM Society.

[15]  Nivedha, R., Nallusamy, S., Subash, E., Venkadesh, V., Vignesh S., & Vinoth kumar, P. (2018). Minimization of rejection rate using lean six sigma tool in medium scale manufacturing industry, International journal of mechanical engineering and technology, 9(1), 1184–1194.

[16]   Arunagiri, P., & Gnanavelbabu, A. (2014). Identification of major lean production waste in automobile industries using weighted average method. Procedia engineering97, 2167-2175.

[17]  Dinis-Carvalho, J., Guimaraes, L., Sousa, R. M., & Leao, C. P. (2018). Waste identification diagram and value stream mapping: A comparative analysis. International journal of lean six sigma.

[18]  Saravana Kumar, T.,  Soumya, PR., Minu Manjari, V., Aishvariya, RE., & Akalya, N. (2017) Implementation of lean manufacturing tools in Garment industry. International journal of latest technology in engineering, management & applied science (IJLTEMAS), 6(3).