Track: Lean

Abstract

In today’s competitive market, companies strive to utilize opportunities to survive long-term and remain competitive. Lean Manufacturing is a broadly perceived tool among industries. Organizations and companies are struggling with the new customer-driven and competitive market. In order to overcome this challenge, they have turned into Lean Manufacturing utilization. The focus of this study is on reducing cycle time by applying lean manufacturing tools and techniques at Kautex Textron Corporation. The first step of the study was process mapping to have a clear understanding of the whole process of plastic fuel tank production and then, other required data were gathered and measured for the next steps. Pareto Charts, 4W 1H, Fishbone, and 5Why were utilized to identify the problems and to find out where exactly the waste is occurring in the production line. After a root cause analysis, MODAPTS and 5S techniques were applied to reduce the wastes which were mainly due to the excessive operator movements in conjunction with a disorganized workplace. Operator movements in all stations were observed and recorded and then unnecessary movements were identified as waste and therefore, eliminated. Utilizing root cause analysis tools, we found out that the waste is occurring due to a messy environment. Needless to say that 5S is the most proper tool to increase productivity by providing a safe and efficient workplace. To obtain better results, some further suggestions were recommended such as providing user-friendly containers and conveyors for components and changing the layout for more convenience of transportation and waste elimination.