This study applies lean management approaches in grinding wheel production, such as value-stream mapping, quick changeover, and line balancing to decrease lead time, work-in-process, changeover time, and increase quality and productivity. Customer orders of grinding wheel products have the characteristics of low volume and wide variety while the production process is labor-intensive as well. Among all processes of grinding wheel production, the mixed process and burned process are the most time-consuming steps, any unexpected breakdown will significantly decrease available capacity and lead to bottleneck in production, which causes additional cost.

By illustrating the As-Is model of value-stream mapping after collecting production system information and analyzing the current state of manufacturing production, we set the goal for improvement. After implementing capacity balance improvements and importing the quick changeover method, the To-Be model was developed to evaluate the improvement by reducing non-value-adding waste, including waiting, transportation and inventory. This research combines theory and practical applications, hoping to effectively improve grinding wheel production to increase production effectiveness and efficiency, therefore enhancing the competitiveness of the traditional manufacturing industry.

Thomas Hsieh

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The Application of Lean Management to Improve Productivity – A Case Study of Kinik Company