Track: Quality Control and Management

Abstract

Lean approach has been applied in the production floor in recent times. Started in the automotive industry lean tools have been applied in different production and management floors. Lean principles are adopted in a reputed plastic manufacturing company of Dhaka, Bangladesh with a view to increasing financial profit by increasing efficiency and reducing waste. Value stream mapping (VSM), Cause and effect diagram, Pareto analysis, control charts, key lean tools have been used to identify the improvement opportunists, DMIAC (Design, Measure, Improve, Analyze and Control) and 5s have been used for continuous improvement, Control Chart. A team was formed consisting 7 workers and then trained about these tools. After one month of implementing these tools and techniques it was found that that lead time was reduced by 10%. Total value addition time increased from 34310hr to 35564hr (3.5 % increased). Total production increased from 41154890 to 43009168 pieces (4.3% increased), defective products decreased from 2050736 to 1793154 pieces (12.56% decreased), sigma level improved from 3.18σ to 3.21σ, manufacturing lead time reduced from 19 days to 18 days for every type of product, process time reduced from 18sec to 15sec for every type of product, non-value-added time reduced from 36sec to 26sec, process efficiency increased from 33.33% to 36.58%. This paper demonstrates the use of the above-mentioned tools and discuss their application in LP initiative in a manufacturing plant.