Productivity Improvement through Implementation of Lean tools

Abstract

In the competitive manufacturing industry, cost-effective production is crucial for success. A key element in achieving operational efficiency and minimizing costs is an effective facility layout. This paper examines the packaging process for PU foam rolls, employing LEAN tools such as activity analysis, 5W2H, spaghetti diagram, and standardized work sheet among others. By identifying non-value adding steps and areas for improvement, insights were gained. Additionally, optimized machine layout was developed using From/To charts and CRAFT tool. The objective was to enhance process efficiency by analyzing distances, tools, and time for material handling and redesigning the layout accordingly. The results showed significant improvements, including reduced transportation distance (76.2%), time spent (63.3%), operational costs (50%), and increased operational efficiency (164.2%). This study highlights the effectiveness of LEAN tools and emphasizes the importance of production layout in enhancing efficiency and reducing costs for manufacturing companies to stay competitive.