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Reduce Manufacturing Lead Time Through PDCA And Waste Elimination In Metal Casting Company: A Case Study

In the late 1900s and early 2000s, there were a few newly founded foundries that were better organized and used contemporary machinery to make high-quality iron and steel castings in small and medium-sized enterprises (SMEs). The late delivery of a particular product was one of the most important...

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Main Author: Azhan, Anis Masturina
Format: Monograph
Language:English
Published: Universiti Sains Malaysia 2022
Subjects:
T Technology
TJ Mechanical engineering and machinery
Online Access:http://eprints.usm.my/55457/1/Reduce%20Manufacturing%20Lead%20Time%20Through%20Pdca%20And%20Waste%20Elimination%20In%20Metal%20Casting%20Company%20A%20Case%20Study_Anis%20Masturina%20Azhan.pdf
http://eprints.usm.my/55457/
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spelling my.usm.eprints.55457 http://eprints.usm.my/55457/ Reduce Manufacturing Lead Time Through PDCA And Waste Elimination In Metal Casting Company: A Case Study Azhan, Anis Masturina T Technology TJ Mechanical engineering and machinery In the late 1900s and early 2000s, there were a few newly founded foundries that were better organized and used contemporary machinery to make high-quality iron and steel castings in small and medium-sized enterprises (SMEs). The late delivery of a particular product was one of the most important challenges experienced by foundry experts and researchers throughout manufacturing. Consequently, the customer experienced unsatisfactory service. Utilizing the PDCA continuous improvement cycle is necessary since it is a crucial tool for raising the quality of a product over time and minimizing waste. To save time, it was used in an attempt in this thesis study. The major purpose of this thesis is to reduce the manufacturing lead time of metal casting using the PDCA cycle and waste elimination in the administration department. The potential waste that might occur during the manufacturing lead time has been identified via a review of the relevant literature and the implementation of fishbone diagrams in the root cause analysis step. Then, as a potential countermeasure, the WITNESS Horizon simulation was used to examine and compare production line models with and without motion waste. This thesis found that the simulation model 3 showed the lowest lead-time compared to simulation model 1 and 2 with the elimination of all motion waste at the discussion section. It can be concluded that with the implementation of PDCA cycle in this thesis, the lead-time of metal casting process has been improved by 4.34% systematically. It was proven that the PDCA cycle is an excellent tool to reduce the metal casting process. Universiti Sains Malaysia 2022-07-24 Monograph NonPeerReviewed application/pdf en http://eprints.usm.my/55457/1/Reduce%20Manufacturing%20Lead%20Time%20Through%20Pdca%20And%20Waste%20Elimination%20In%20Metal%20Casting%20Company%20A%20Case%20Study_Anis%20Masturina%20Azhan.pdf Azhan, Anis Masturina (2022) Reduce Manufacturing Lead Time Through PDCA And Waste Elimination In Metal Casting Company: A Case Study. Project Report. Universiti Sains Malaysia, Pusat Pengajian Kejuruteraan Mekanikal. (Submitted)
institution Universiti Sains Malaysia
building Hamzah Sendut Library
collection Institutional Repository
continent Asia
country Malaysia
content_provider Universiti Sains Malaysia
content_source USM Institutional Repository
url_provider http://eprints.usm.my/
language English
topic T Technology
TJ Mechanical engineering and machinery
spellingShingle T Technology
TJ Mechanical engineering and machinery
Azhan, Anis Masturina
Reduce Manufacturing Lead Time Through PDCA And Waste Elimination In Metal Casting Company: A Case Study
description In the late 1900s and early 2000s, there were a few newly founded foundries that were better organized and used contemporary machinery to make high-quality iron and steel castings in small and medium-sized enterprises (SMEs). The late delivery of a particular product was one of the most important challenges experienced by foundry experts and researchers throughout manufacturing. Consequently, the customer experienced unsatisfactory service. Utilizing the PDCA continuous improvement cycle is necessary since it is a crucial tool for raising the quality of a product over time and minimizing waste. To save time, it was used in an attempt in this thesis study. The major purpose of this thesis is to reduce the manufacturing lead time of metal casting using the PDCA cycle and waste elimination in the administration department. The potential waste that might occur during the manufacturing lead time has been identified via a review of the relevant literature and the implementation of fishbone diagrams in the root cause analysis step. Then, as a potential countermeasure, the WITNESS Horizon simulation was used to examine and compare production line models with and without motion waste. This thesis found that the simulation model 3 showed the lowest lead-time compared to simulation model 1 and 2 with the elimination of all motion waste at the discussion section. It can be concluded that with the implementation of PDCA cycle in this thesis, the lead-time of metal casting process has been improved by 4.34% systematically. It was proven that the PDCA cycle is an excellent tool to reduce the metal casting process.
format Monograph
author Azhan, Anis Masturina
author_facet Azhan, Anis Masturina
author_sort Azhan, Anis Masturina
title Reduce Manufacturing Lead Time Through PDCA And Waste Elimination In Metal Casting Company: A Case Study
title_short Reduce Manufacturing Lead Time Through PDCA And Waste Elimination In Metal Casting Company: A Case Study
title_full Reduce Manufacturing Lead Time Through PDCA And Waste Elimination In Metal Casting Company: A Case Study
title_fullStr Reduce Manufacturing Lead Time Through PDCA And Waste Elimination In Metal Casting Company: A Case Study
title_full_unstemmed Reduce Manufacturing Lead Time Through PDCA And Waste Elimination In Metal Casting Company: A Case Study
title_sort reduce manufacturing lead time through pdca and waste elimination in metal casting company: a case study
publisher Universiti Sains Malaysia
publishDate 2022
url http://eprints.usm.my/55457/1/Reduce%20Manufacturing%20Lead%20Time%20Through%20Pdca%20And%20Waste%20Elimination%20In%20Metal%20Casting%20Company%20A%20Case%20Study_Anis%20Masturina%20Azhan.pdf
http://eprints.usm.my/55457/
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score 13.211869

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