Implementation of lean manufacturing to enhance the efficiency of acrylic resins production process

Authors

  • Sahrupi Sahrupi Universitas Serang Raya
  • Gerry Anugrah Dwiputra Universitas Serang Raya
  • Uswatun Chasanah Universitas Serang Raya

DOI:

https://doi.org/10.30656/jsmi.v4i1.1488

Keywords:

Acrylic resins, Lead time, Lean manufacturing, Waste

Abstract

High lead time processing of acrylic resins leads to the production of products to consumer undergoes and high-production costs. This study aims to reduce lead time by analyzing various activities that have value-added, non-value-added, and necessary non-value-added. The research is conducted using lean manufacturing approaches on acrylic resin production processes. The analysis shows that the activity of delay and transportation is a contributor of waste that occurs in the production process of acrylic resins. Improvements by minimizing both activities in the are thining tank, reactor, and monomer tank can increase the efficiency of the production process. The improvement results show a decrease in lead time from 1298 minutes to 1075 minutes. This study demonstrates that lean manufacturing can improve the time process efficiency of 17.18%, which means the output ratio will increase by around 17.18% in a process.

References

A. N. A. Wahab, M. Mukhtar, and R. Sulaiman, “A Conceptual Model of Lean Manufacturing Dimensions,†Procedia Technol., vol. 11, pp. 1292–1298, 2013.

R. Čiarnienė and M. Vienažindienė, “Lean Manufacturing: Theory And Practice,†Econ. Manag., vol. 17, no. 2, pp. 726–732, Aug. 2012.

R. Sundar, A. N. Balaji, and R. M. S. Kumar, “A Review on Lean Manufacturing Implementation Techniques,†Procedia Eng., vol. 97, pp. 1875–1885, 2014.

G. Miller, J. Pawloski, and C. R. Standridge, “A case study of lean, sustainable manufacturing,†J. Ind. Eng. Manag., vol. 3, no. 1, pp. 11–32, 2010.

E. Andrés-López, I. González-Requena, and A. Sanz-Lobera, “Lean Service: Reassessment of Lean Manufacturing for Service Activities,†Procedia Eng., vol. 132, pp. 23–30, 2015.

R. R. Fullerton, F. A. Kennedy, and S. K. Widener, “Lean manufacturing and firm performance: The incremental contribution of lean management accounting practices,†J. Oper. Manag., vol. 32, no. 7–8, pp. 414–428, Nov. 2014.

J. R. Jadhav, S. S. Mantha, and S. B. Rane, “Exploring barriers in lean implementation,†Int. J. Lean Six Sigma, vol. 5, no. 2, pp. 122–148, May 2014.

P. Achanga, E. Shehab, R. Roy, and G. Nelder, “Critical success factors for lean implementation within SMEs,†J. Manuf. Technol. Manag., vol. 17, no. 4, pp. 460–471, Jun. 2006.

M. AlManei, K. Salonitis, and Y. Xu, “Lean Implementation Frameworks: The Challenges for SMEs,†Procedia CIRP, vol. 63, pp. 750–755, 2017.

T. Bortolotti, S. Boscari, and P. Danese, “Successful lean implementation: Organizational culture and soft lean practices,†Int. J. Prod. Econ., vol. 160, pp. 182–201, Feb. 2015.

T. Wagner, C. Herrmann, and S. Thiede, “Industry 4.0 Impacts on Lean Production Systems,†Procedia CIRP, vol. 63, pp. 125–131, 2017.

B. Mrugalska and M. K. Wyrwicka, “Towards Lean Production in Industry 4.0,†Procedia Eng., vol. 182, pp. 466–473, 2017.

K. B. Stone, “Four decades of lean: a systematic literature review,†Int. J. Lean Six Sigma, vol. 3, no. 2, pp. 112–132, Jun. 2012.

M. K. Wyrwicka and B. Mrugalska, “Mirages of Lean Manufacturing in Practice,†Procedia Eng., vol. 182, pp. 780–785, 2017.

K. Elnamrouty and M. S. Abushaaban, “Seven wastes elimination targeted by lean manufacturing case study “gaza strip manufacturing firms’’,†Seven wastes Elimin. Target. by lean Manuf. case study “gaza strip Manuf. firms’’, vol. 1, no. 2, 2013.

A. Sanders, C. Elangeswaran, and J. Wulfsberg, “Industry 4.0 implies lean manufacturing: Research activities in industry 4.0 function as enablers for lean manufacturing,†J. Ind. Eng. Manag., vol. 9, no. 3, p. 811, Sep. 2016.

A. R. Rahani and M. Al-Ashraf, “Production Flow Analysis through Value Stream Mapping: A Lean Manufacturing Process Case Study,†Procedia Eng., vol. 41, pp. 1727–1734, 2012.

U. K. Teichgräber and M. de Bucourt, “Applying value stream mapping techniques to eliminate non-value-added waste for the procurement of endovascular stents,†Eur. J. Radiol., vol. 81, no. 1, pp. e47–e52, Jan. 2012.

A. P. Lacerda, A. R. Xambre, and H. M. Alvelos, “Applying Value Stream Mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry,†Int. J. Prod. Res., vol. 54, no. 6, pp. 1708–1720, Mar. 2016.

B. Singh, S. K. Garg, S. K. Sharma, and C. Grewal, “Lean implementation and its benefits to production industry,†Int. J. Lean Six Sigma, vol. 1, no. 2, pp. 157–168, May 2010.

R. Shah and P. T. Ward, “Defining and developing measures of lean production,†J. Oper. Manag., vol. 25, no. 4, pp. 785–805, Jun. 2007.

J. Bhamu and K. Singh Sangwan, “Lean manufacturing: literature review and research issues,†Int. J. Oper. Prod. Manag., vol. 34, no. 7, pp. 876–940, Jul. 2014.

A. Mousa, “Lean, Six sigma and Lean six sigma overview,†Int. J. Sci. Eng. Res., vol. 4, no. 5, pp. 1137–1153, 2013.

S. Mostafa and J. Dumrak, “Waste Elimination for Manufacturing Sustainability,†Procedia Manuf., vol. 2, pp. 11–16, 2015.

J. P. Womack and D. T. Jones, “Lean Thinking—Banish Waste and Create Wealth in your Corporation,†in Journal of the Operational Research Society, vol. 48, no. 11, Taylor & Francis, 1997, pp. 1148–1148.

A. Jaffar, S. Kasolang, Z. A. Ghaffar, N. S. Mohamad, and M. K. F. Mohamad, “Management of Seven Wastes: A Case Study in an Automotive Vendor,†J. Teknol., vol. 76, no. 6, 2015.

E. W. Dickson, S. Singh, D. S. Cheung, C. C. Wyatt, and A. S. Nugent, “Application of Lean Manufacturing Techniques in the Emergency Department,†J. Emerg. Med., vol. 37, no. 2, pp. 177–182, Aug. 2009.

Downloads

Published

2020-07-28

Issue

Vol. 4 No. 1 (2020)

Section

Research Article

License

All articles in Jurnal Sistem dan Manajemen Industri can be disseminated provided they include the identity of the article and the source of the article Jurnal Sistem dan Manajemen Industri. The publisher is not responsible for the contents of the article. The content of the article is the sole responsibility of the author

Creative Commons License

Jurnal Sistem dan Manajemen Industri is licensed under a Creative Commons Attribution-NonCommercial-ShareAlike 4.0 International License.

How to Cite

[1]
“Implementation of lean manufacturing to enhance the efficiency of acrylic resins production process”, j. sist. manaj. ind., vol. 4, no. 1, pp. 50–60, Jul. 2020, doi: 10.30656/jsmi.v4i1.1488.
Crossref
Scopus
Google Scholar
Europe PMC