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Lean manufacturing based space utilization and motionwaste reduction for efficiency enhancement in a machiningshop: a case study
Authors:
Leon Dube1
,
Kapil Gupta1
1University of Johannesburg, Mechanical and Industrial Engineering Technology, Johannesburg, South Africa
Received: 24 June 2023
Revised: 6 September 2023
Accepted: 14 September 2023
Published: 30 September 2023
Abstract:
Lean manufacturing is a corporate strategy that focuses on continually improving all processes in the production environment by reducing waste and costs. The implementation of lean manufacturing systems will always begin within the existing facility layout. Therefore, the arrangement of the facility has a tremendous impact on the company’s development and space utilization. This research addresses possible research gaps related to the industry’s requirement for successful lean manufacturing and space utilization. In this research, an integration of lean techniques and facility layout planning has been used to optimize the workshop operation by implementing 5S and Systematic Layout Planning to rearrange machines, which eliminated waste caused by unnecessary motion. As a result, out of two alternatives of facility layout proposed, the process efficiency is improved from 53% to 66%. An efficient facility layout helps production schedules run more smoothly while minimizing costs and enhancing space utilization. It has contributed to create a safe and healthy work environment. The research is limited to optimizing space utilization and attempts to eliminate excessive motion of employees and equipment in the machining shop of a mechanical workshop. The need to close the implementation gap for lean and space utilization will make a substantial contribution to long-term industrial sustainability.
Keywords:
Layout, lean manufacturing, 5S, productivity, waste, space utilization
References:
[1] P. Jones, P. Robinson, Operations management. Oxford University Press, United Kingdom, 2012.
[2] L. Wilson, How to implement lean manufacturing. McGraw-Hill, USA, 2010.
[3] P. Jana, M. Tiwari, Industrial engineering and manufacturing. In: P. Jana and M. Tiwari, eds. Industrial engineering in apparel manufacturing. Apparel Resource PVt. Ltd, New Delhi, 2018: 267-283.
[4] J. Nelson, Becoming a Lean Library. In: J. Nelson, ed. Chapter 3 – Pull versus push: Lessons from Lean Manufacturing. Chandos Publishing, United Kingdom, 2016: 29-49.
[5] S.B. Naik, S. Kallurkar, A Literature Review on Efficient Plant Layout Design. International Journal of Industrial Engineering Research and Development, 7(2), 2016: 43-51.
https://doi.org/10.34218/IJIERD.7.2.2016.005
[6] D. Rahmanasari, W. Sutopo, J.M. Rohani, Implementation of Lean Manufacturing Process to Reduce Waste: A Case Study. IOP Conference Series: Materials Science and Engineering, 1096, 2021: 012006. https://doi.org/10.1088/1757-899X/1096/1/012006
[7] N.T. Putri, L.D. Dona, Application of lean manufacturing concept for redesigning facilities layout in Indonesian home-food industry. The TQM Journal, 31(5), 2019: 815-830. https://doi.org/10.1108/TQM-02-2019-0033
[8] L. Wilson, How to Implement Lean Manufacturing. McGraw-Hill Education, New York, Chicago, San Francisco, London, 2015.
[9] I. Tajri, A. Chekaoui, Modeling the complexity of the relationship (Lean, company, employee and cognitive ergonomics) case of Moroccan SMEs. 2015 International Conference on Industrial Engineering and Systems Management (IESM), 21-23 October 2015, Seville, Spain.
https://doi.org/10.1109/IESM.2015.7380318
[10] B. Suhardi, N. Anisa, P.W. Laksono, Minimizing waste using lean manufacturing and ECRS principle in Indonesian furniture industry. Cogent Engineering, 6(1), 2019: 1567019.
https://doi.org/10.1080/23311916.2019.1567019
[11] M.B. Patil, V.G. Surange, S.N. TeliBhushi, Implementation of Lean Manufacturing Strategy in Label Printing Industry Using Value Stream Mapping. 2022 Advances in Science and Engineering Technology International Conferences (ASET), 21-24 February 2022, Dubai, United Arab Emirates.
https://doi.org/10.1109/ASET53988.2022.9734954
[12] S. Sapkal, A. Joshi, Lean Manufacturing Implementation in Crankshaft Manufacturing Company. In: Phanden, R.K., Mathiyazhagan, K., Kumar, R., Paulo Davim, J. (eds) Advances in Industrial and Production Engineering. Lecture Notes in Mechanical Engineering. Springer, Singapore, 2021: 629-636.
https://doi.org/10.1007/978-981-33-4320-7_56
[13] K. Gupta, A review on Implementation of 5S for Workplace Management. Journal of Applied Research on Industrial Engineering, 9(3), 2022: 323-330. https://doi.org/10.22105/jarie.2021.292741.1347
[14] P.A.M. Simons, J. Benders, W. Marneffe, M. Pijls-Johannesma, D. Vandijck, Workshops as a useful tool to better understand care professionals view of a lean change program. International Journal of Health Care Quality Assurance, 28(1), 2015: 64-74. https://doi.org/10.1108/IJHCQA-01-2014-0007
[15] P. Cordeiro, J.C. Sa, A. Pata, M.A. Goncalves, G. Santos, F.J.G. Silva, The Impact of lean Tools on Safety-Case Study. In: Arezes, P., et al. Occupational and Environmental Safety and Health II. Studies in Systems, Decision and Control. Springer, Cham, 277, 2020: 151-159. https://doi.org/10.1007/978-3-030-41486-3_17
[16] P. Rufe, Fundamentals of manufacturing. Society of Manufacturing Engineers (SME), Southfield, USA, 2016.
[17] K. Frank, Strategic facility planning (SFP). Work Study, 48(5), 1999: 176-181.
https://doi.org/10.1108/00438029910279394
[18] H. Dale, P. P. Besterfield, Quality improvement. Pearson Education, USA, 2021.
[19] P. Jana, Lean supply chain management. In: J. Prabir and M. Tiwari, eds. Lean Tools in Apparel Manufacturing. Woodhead Publishing, 2021: 381-398.
[20] I. Rizkya, K. Syahputri, R. M. Sari, I. Siregar, 5S Implementation in welding workshop-a Lean Tool in Waste Minimization. IOP Conference Series: Materials Science and Engineering, 505, 2019: 012018. https://doi.org/10.1088/1757-899X/505/1/012018
[21] J. Swati, K. Tarun, Systematic Layout Planning: A Review of Improvement in Approach to Pulse Processing Mills. International Research Journal of Engineering and Technology, 04(05), 2017: 503-507.
[22] Monica, M. Ashwani, A review of procedural approaches available for handling the layout problems. International Journal of Emerging Trends in Research, 1(5), 2016: 06-11.
[23] Y. Kazancoglu, Y.D. Ozkan-Ozen, Lean in higher education: A proposed model for lean transformation in a business school with MCDM application. Quality Assurance in Education, 27(1), 2019: 82-102. https://doi.org/10.1108/QAE-12-2016-0089
[24] K.A. El-Namrouty, M.S. AbuShaaban, Seven wastes elimination targeted by lean manufacturing case study gaza strip manufacturing firms. International Journal of Economics, Finance and Management Sciences, 1(2), 2013: 68-80.
© 2023 by the authors. This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 10
Number 1
March 2025
Last Edition
Volume 10
Number 1
March 2025
How to Cite
L. Dube, K. Gupta, Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study. Applied Engineering Letters, 8(3), 2023: 121–130.
https://doi.org/10.18485/aeletters.2023.8.3.4
More Citation Formats
Dube, L., & Gupta, K. (2023). Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study. Applied Engineering Letters, 8(3), 121–130. https://doi.org/10.18485/aeletters.2023.8.3.4
Dube, Leon, and Kapil Gupta. “Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study.” Applied Engineering Letters, vol. 8, no. 3, 2023, pp. 121–30, https://doi.org/10.18485/aeletters.2023.8.3.4.
Dube Leon, and Kapil Gupta. 2023. “Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study.” Applied Engineering Letters 8 (3): 121–30. https://doi.org/10.18485/aeletters.2023.8.3.4.
Dube, L. and Gupta, K. (2023). Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study. Applied Engineering Letters, 8(3), pp.121–130. doi: 10.18485/aeletters.2023.8.3.4.
Lean manufacturing based space utilization and motionwaste reduction for efficiency enhancement in a machiningshop: a case study
Authors:
Leon Dube1
,
Kapil Gupta1
1University of Johannesburg, Mechanical and Industrial Engineering Technology, Johannesburg, South Africa
Received: 24 June 2023
Revised: 6 September 2023
Accepted: 14 September 2023
Published: 30 September 2023
Abstract:
Lean manufacturing is a corporate strategy that focuses on continually improving all processes in the production environment by reducing waste and costs. The implementation of lean manufacturing systems will always begin within the existing facility layout. Therefore, the arrangement of the facility has a tremendous impact on the company’s development and space utilization. This research addresses possible research gaps related to the industry’s requirement for successful lean manufacturing and space utilization. In this research, an integration of lean techniques and facility layout planning has been used to optimize the workshop operation by implementing 5S and Systematic Layout Planning to rearrange machines, which eliminated waste caused by unnecessary motion. As a result, out of two alternatives of facility layout proposed, the process efficiency is improved from 53% to 66%. An efficient facility layout helps production schedules run more smoothly while minimizing costs and enhancing space utilization. It has contributed to create a safe and healthy work environment. The research is limited to optimizing space utilization and attempts to eliminate excessive motion of employees and equipment in the machining shop of a mechanical workshop. The need to close the implementation gap for lean and space utilization will make a substantial contribution to long-term industrial sustainability.
Keywords:
Layout, lean manufacturing, 5S, productivity, waste, space utilization
References:
[1] P. Jones, P. Robinson, Operations management. Oxford University Press, United Kingdom, 2012.
[2] L. Wilson, How to implement lean manufacturing. McGraw-Hill, USA, 2010.
[3] P. Jana, M. Tiwari, Industrial engineering and manufacturing. In: P. Jana and M. Tiwari, eds. Industrial engineering in apparel manufacturing. Apparel Resource PVt. Ltd, New Delhi, 2018: 267-283.
[4] J. Nelson, Becoming a Lean Library. In: J. Nelson, ed. Chapter 3 – Pull versus push: Lessons from Lean Manufacturing. Chandos Publishing, United Kingdom, 2016: 29-49.
[5] S.B. Naik, S. Kallurkar, A Literature Review on Efficient Plant Layout Design. International Journal of Industrial Engineering Research and Development, 7(2), 2016: 43-51.
https://doi.org/10.34218/IJIERD.7.2.2016.005
[6] D. Rahmanasari, W. Sutopo, J.M. Rohani, Implementation of Lean Manufacturing Process to Reduce Waste: A Case Study. IOP Conference Series: Materials Science and Engineering, 1096, 2021: 012006. https://doi.org/10.1088/1757-899X/1096/1/012006
[7] N.T. Putri, L.D. Dona, Application of lean manufacturing concept for redesigning facilities layout in Indonesian home-food industry. The TQM Journal, 31(5), 2019: 815-830. https://doi.org/10.1108/TQM-02-2019-0033
[8] L. Wilson, How to Implement Lean Manufacturing. McGraw-Hill Education, New York, Chicago, San Francisco, London, 2015.
[9] I. Tajri, A. Chekaoui, Modeling the complexity of the relationship (Lean, company, employee and cognitive ergonomics) case of Moroccan SMEs. 2015 International Conference on Industrial Engineering and Systems Management (IESM), 21-23 October 2015, Seville, Spain.
https://doi.org/10.1109/IESM.2015.7380318
[10] B. Suhardi, N. Anisa, P.W. Laksono, Minimizing waste using lean manufacturing and ECRS principle in Indonesian furniture industry. Cogent Engineering, 6(1), 2019: 1567019.
https://doi.org/10.1080/23311916.2019.1567019
[11] M.B. Patil, V.G. Surange, S.N. TeliBhushi, Implementation of Lean Manufacturing Strategy in Label Printing Industry Using Value Stream Mapping. 2022 Advances in Science and Engineering Technology International Conferences (ASET), 21-24 February 2022, Dubai, United Arab Emirates.
https://doi.org/10.1109/ASET53988.2022.9734954
[12] S. Sapkal, A. Joshi, Lean Manufacturing Implementation in Crankshaft Manufacturing Company. In: Phanden, R.K., Mathiyazhagan, K., Kumar, R., Paulo Davim, J. (eds) Advances in Industrial and Production Engineering. Lecture Notes in Mechanical Engineering. Springer, Singapore, 2021: 629-636.
https://doi.org/10.1007/978-981-33-4320-7_56
[13] K. Gupta, A review on Implementation of 5S for Workplace Management. Journal of Applied Research on Industrial Engineering, 9(3), 2022: 323-330. https://doi.org/10.22105/jarie.2021.292741.1347
[14] P.A.M. Simons, J. Benders, W. Marneffe, M. Pijls-Johannesma, D. Vandijck, Workshops as a useful tool to better understand care professionals view of a lean change program. International Journal of Health Care Quality Assurance, 28(1), 2015: 64-74. https://doi.org/10.1108/IJHCQA-01-2014-0007
[15] P. Cordeiro, J.C. Sa, A. Pata, M.A. Goncalves, G. Santos, F.J.G. Silva, The Impact of lean Tools on Safety-Case Study. In: Arezes, P., et al. Occupational and Environmental Safety and Health II. Studies in Systems, Decision and Control. Springer, Cham, 277, 2020: 151-159. https://doi.org/10.1007/978-3-030-41486-3_17
[16] P. Rufe, Fundamentals of manufacturing. Society of Manufacturing Engineers (SME), Southfield, USA, 2016.
[17] K. Frank, Strategic facility planning (SFP). Work Study, 48(5), 1999: 176-181.
https://doi.org/10.1108/00438029910279394
[18] H. Dale, P. P. Besterfield, Quality improvement. Pearson Education, USA, 2021.
[19] P. Jana, Lean supply chain management. In: J. Prabir and M. Tiwari, eds. Lean Tools in Apparel Manufacturing. Woodhead Publishing, 2021: 381-398.
[20] I. Rizkya, K. Syahputri, R. M. Sari, I. Siregar, 5S Implementation in welding workshop-a Lean Tool in Waste Minimization. IOP Conference Series: Materials Science and Engineering, 505, 2019: 012018. https://doi.org/10.1088/1757-899X/505/1/012018
[21] J. Swati, K. Tarun, Systematic Layout Planning: A Review of Improvement in Approach to Pulse Processing Mills. International Research Journal of Engineering and Technology, 04(05), 2017: 503-507.
[22] Monica, M. Ashwani, A review of procedural approaches available for handling the layout problems. International Journal of Emerging Trends in Research, 1(5), 2016: 06-11.
[23] Y. Kazancoglu, Y.D. Ozkan-Ozen, Lean in higher education: A proposed model for lean transformation in a business school with MCDM application. Quality Assurance in Education, 27(1), 2019: 82-102. https://doi.org/10.1108/QAE-12-2016-0089
[24] K.A. El-Namrouty, M.S. AbuShaaban, Seven wastes elimination targeted by lean manufacturing case study gaza strip manufacturing firms. International Journal of Economics, Finance and Management Sciences, 1(2), 2013: 68-80.
© 2023 by the authors. This work is licensed under a Creative Commons Attribution-NonCommercial 4.0 International License (CC BY-NC 4.0)
Volume 10
Number 1
March 2025
Last Edition
Volume 10
Number 1
March 2025
How to Cite
L. Dube, K. Gupta, Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study. Applied Engineering Letters, 8(3), 2023: 121–130.
https://doi.org/10.18485/aeletters.2023.8.3.4
More Citation Formats
Dube, L., & Gupta, K. (2023). Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study. Applied Engineering Letters, 8(3), 121–130. https://doi.org/10.18485/aeletters.2023.8.3.4
Dube, Leon, and Kapil Gupta. “Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study.” Applied Engineering Letters, vol. 8, no. 3, 2023, pp. 121–30, https://doi.org/10.18485/aeletters.2023.8.3.4.
Dube Leon, and Kapil Gupta. 2023. “Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study.” Applied Engineering Letters 8 (3): 121–30. https://doi.org/10.18485/aeletters.2023.8.3.4.
Dube, L. and Gupta, K. (2023). Lean Manufacturing Based Space Utilization and Motion Waste Reduction for Efficiency Enhancement in a Machining Shop: A Case Study. Applied Engineering Letters, 8(3), pp.121–130. doi: 10.18485/aeletters.2023.8.3.4.