Using Lean Manufacturing to Eliminate Waste in a Manufacturing Company - A Case Study
摘要
The aim of the study was to improve production efficiency in a manufacturing company by identifying and eliminating waste. The identification was based on the analysis of the production process and the data collected, and the types of wastage were classified according to the Toyota Production System's categorisation of losses. The measures taken to eliminate waste were based on optimising inventory management and improving the production planning process. To achieve this, the company introduced an inventory management strategy based on maintaining a safety stock to minimise delays caused by the lack of raw materials in the warehouse. Weekly production planning was then implemented based on a demand-driven strategy. To facilitate the production planning and inventory management processes, a tool in MS Excel was developed to generate a production plan based on current demand and to monitor raw material consumption. Tests and training sessions on the use of the tool were then organised in the company to ensure its successful implementation. Finally, the intensity of each type of waste was re-measured and compared with that recorded before the changes were made. Based on this comparison, an analysis was made of the effectiveness of the changes made in terms of eliminating waste and improving efficiency.