The small and medium enterprises (SMEs) in the motor engine repair sector for mining equipment face significant challenges, including inefficient spare parts management and reliance on third-party repairs. These issues lead to delays and inconsistencies, affecting the overall efficiency and productivity of the mining operations they support. To address these challenges, this study proposed a production model based on Lean Manufacturing principles, including Poka Yoke, Standardized Work, and the Analytic Hierarchy Process (AHP). The model aimed to streamline workflows, improve quality control, and enhance operational efficiency through systematic error prevention and decision-making frameworks.
The implementation of the proposed model resulted in a 25% reduction in time lost per component, decreasing from 3.16 hours to 2.39 hours. Additionally, repair capacity increased by 7.77 hours per component, and the use of Poka Yoke led to a 32.6% reduction in errors related to spare parts. The standardization of third-party jobs through Kaizen and AHP further reduced non-compliant work by 9%.
The study's findings demonstrated significant improvements in the operational efficiency of SMEs in the motor engine repair sector, contributing to the overall productivity and profitability of the mining industry. This research provides a robust framework for addressing operational challenges and highlights the socio-economic benefits of adopting Lean Manufacturing principles.
Future research should explore further integration of advanced technologies and continuous improvement methodologies to sustain the gains achieved and to adapt to evolving industry needs.