Abstract

APPLICATION OF SOME LEAN PRODUCTION TOOLS TO IMPROVE THE PRODUCTION PROCESS - AN APPLIED STUDY IN THE GENERAL COMPANY FOR FOOD PRODUCTS/ YOGURT FACTORY

Waffa Talib Al- baher, Assis. Prof. Dr. Hala Hamad Magod

Volume: 10 Issue: 4 2020

Abstract:

Purpose – The researcher noticed the low production levels of some factories, including the yogurt factory, as well as the appearance of spoilage, and a delay in the production process, as well as the deterioration of the situation in the work environment inside the factories. From a decrease in the level of lighting, ventilation, energy, noise and other environmental aspects affecting the work environment. Here, the problem can be identified through a number of questions, namely: 1. Can some lean production tools be applied in the company's factories? 2. Does the lean production method contribute to the elimination of the problems experienced by the production process in the factories? 3. Does lean production contribute to improving the production process? Is it possible to apply some of the tools of sustainable and lean production in the yogurt factory? 4. How does the sustainable value map contribute to improving the production process in the yogurt factory. Design/methodology/approach - The study adopted an applied study approach in identifying the reality of the yogurt production plant in the General Company for Food Products of Abu Ghraib factories, identifying problems and their treatments and proposing appropriate solutions and their suitability for the subject of the study, through field visits to record observations, collect data, conduct personal interviews, inquire and analyze And to identify the production processes, the problems that occur, and the opinions of working individuals about dealing with those problems in the production process Originality/value – The senior management of the General Company for Food Products helps to build its production plans in a way that conforms to the trends of the times, and to adopt modern scientific methods in managing production processes within the factories. And The scientific importance of the study is reflected in the clarity of the impact and importance of spreading the culture of lean production, as an important method to achieve it in a production company, and the resulting reduction in rejected production, improving performance rates, reducing waste and pollution rates,

DOI: http://doi.org/10.37648/ijrssh.v10i04.009

Back Download

References

• Krajewski, L. J., Ritzman, L. P., & Malhotra, M. K. (2016). Operations management: Processes and supply chains 11thEd, Upper Saddle River, NJ: Pearson.
• Reid, R. D., & Sanders, N. R. (2013), Operations Management, An Integrated Approach, John Wiley & Sons.
• Kurdve, M., Zackrisson, M., Wiktorsson, M., & Harlin, U. (2014). Lean and green integration into production system models–experiences from Swedish industry. Journal of Cleaner Production, 85, 180-190
• Abreu, M. F., Alves, A. C., & Moreira, F. (2017), Lean-Green models for eco-efficient and sustainable production, Energy, 137, 846-853
• Acero, R., Torralba, M., Pérez-Moya, R., & Pozo, J. A. (2020). Value Stream Analysis in Military Logistics: The Improvement in Order Processing Procedure. Applied Sciences, 10(1), 106.
• Found, Pauline. 'Lean and low environmental impact manufacturing.' (2009).
• Haapala, K. R., Zhao, F., Camelio, J., Sutherland, J. W., Skerlos, S. J., Dornfeld, D. A., ... & Rickli, J. L. (2013). A review of engineering research in sustainable manufacturing. Journal of Manufacturing Science and Engineering, 135(4).
• Jaghbeer, Y., Motyka, Y., & Hallstedt, S. (2017). A process for designing lean-and sustainable production. In DS 87-1 Proceedings of the 21st International Conference on Engineering Design (ICED 17) Vol 1: Resource Sensitive Design, Design Research Applications and Case Studies, Vancouver, Canada, 21-25.08. 2017 (pp. 051- 060).
• Järvenpää, E., & Lanz, M. (2019). Lean Manufacturing and Sustainable Development
• Kumar, B., & Rakesh, P. (2017). Kumar: Implementation of Poka Yoke in Needle Bearing Assembly Process. International Journal of Engineering Science Invention, 6(11), 1-10.
• Lacerda, A. P., Xambre, A. R., & Alvelos, H. M. (2016), Applying Value Stream Mapping to eliminate waste: a case study of an original equipment manufacturer for the automotive industry, International Journal of Production Research, 54(6), 1708-1720.
• Mrugalska, B., & Wyrwicka, M. K. (2017). Towards lean production in industry 4.0. Procedia Engineering, 182, 466-473.
• Netland, T. H. (2016). Critical success factors for implementing lean production: the effect of contingencies. International Journal of Production Research, 54(8), 2433-2448.
• Ratnayake, R. M. D. K., & Dinosha, V. (2018). Effectiveness of lean manufacturing layout of a firm within the apparel industry of sri lanka: a case study.
• Sezen, B., & Cankaya, S. Y. (2013), Effects of green manufacturing and eco-innovation on sustainability performance, Procedia-Social and Behavioral Sciences, 99, 154-163.
• Shah, D., & Patel, P. (2018). Productivity improvement by implementing lean manufacturing tools in manufacturing industry. International Research Journal of Engineering and Technology, 5(3), 3-7.
• Chofreh, A. G., Goni, F. A., Ismail, S., Shaharoun, A. M., Klemeš, J. J., & Zeinalnezhad, M. (2016), A master plan for the implementation of sustainable enterprise resource planning systems (part I): concept and methodology, Journal of cleaner production, 136, 176-182.
• Miller, G., Pawloski, J., & Standridge, C. R. (2010). A case study of lean, sustainable manufacturing. Journal of Industrial Engineering and Management (JIEM), 3(1), 11-32.
• Yusup, M. Z., Mahmood, W., Hasrulnizzam, W., & Salleh, M. R. (2015). Review the influence of lean tools and its performance against the index of manufacturing sustainability. Int. J. Agile Systems and Management, 8(2), 116- 131
• Vinodh, S., Arvind, K. R., & Somanaathan, M. (2010). Application of value stream mapping in an Indian camshaft manufacturing organisation. Journal of Manufacturing Technology Management, 21(7), 888-900.
• Sunk, A., Kuhlang, P., Edtmayr, T., & Sihn, W. (2016). Developments of traditional value stream mapping to enhance personal and organisational system and methods competencies. International Journal of Production Research, 55(13), 3732-3746.
• Khodeir, L. M., & Othman, R. (2018). Examining the interaction between lean and sustainability principles in the management process of AEC industry. Ain Shams Engineering Journal, 9(4), 1627-1634
• SWARNA, N. A., & MIA, M. A. S. (2018). Productivity improvement of leather products industry in Bangladesh using lean tools: a case study. Revista de Pielarie Incaltaminte, 18(3), 219.
• Jacobs, Robert F., Chase, Richard B., and Lummus, Rhonda R., 2018, Operations and Supply Chain Management, 15th ed., McGraw-Hill / Irwin, China.
• Francis, A., & Thomas, A. (2019). Integrating Lean Construction and Sustainability via a System Dynamics Framework. In Proc. 27th Annual Conference of the International Group for Lean Construction (IGLC) (pp. 1187- 1196).
• Syahputri, K., Sari, R. M., Tarigan, I. R., & Siregar, I. (2018, February). Application of lean six sigma to waste minimization in cigarette paper industry. In IOP conference series: materials science and engineering (Vol. 309, No. 1, p. 012027). IOP Publishing
• Caldera, H. T. S., Desha, C., & Dawes, L. (2019), Evaluating the enablers and barriers for successful implementation of sustainable business practice in ‘lean’SMEs. Journal of cleaner production, 218, 575-590.