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 |  موضوع: مشروع تخرج بعنوان Improving Productivity Using Lean Manufacturing الإثنين 07 فبراير 2011, 9:10 pm | |
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تذكير بمساهمة فاتح الموضوع : أخوانى فى الله
أحضرت لكم مشروع تخرج بعنوان
Improving productivity Using Lean Manufacturing
Under Supervision
Dr. Mervat A. Badr
Associate Professor, Mechanical Engineering Department
National Research Centre
Ahmed Fathi
Abdalla Shdad
Mark Azeer
Mohamed Ali
Beshoy Naiem
ويتناول الموضوعات الأتية :
TABLE OF CONTENTES
TABLE OF CONTENTES . I
LIST OF FIGURES . V
LIST OF TABLES VIII
1. INTRODUCTION . 1
1. 1. Background .. 1
1. 2. Problem Statement . 1
1. 3. Research Objec ves 2
1. 4. Research Approach .. 3
2. BACKGROUND AND LITERATURE REVIEW . 4
2. 1. History of Lean 4
2. 2. What Is Lean? .. 5
2. 3. Lean Manufacturing Tools and Techniques .. 9
2. 3. 1. Cellular Manufacturing 9
2. 3. 2. Con nuous Improvement 10
2. 3. 3. Just-In-Time .. 12
2. 3. 4. Produc on Smoothing .. 17
2. 3. 5. Standardiza on of Work .. 17
2. 3. 6. Total Produc ve Maintenance . 17
2. 3. 7. Work Cells . 18
2. 3. 8. Total Quality Management . 18
2. 3. 9. Batch Size Reduc on .. 19
2. 3. 10. Other Waste Reduc on Techniques .. 19
2. 4. From Lean Manufacturing to Lean Enterprise .. 20
2. 5. Discrete vs. Con nuous Manufacturing Systems 21
2. 5. 1. Applica on of Lean in Discrete Industry . 25
2. 6. Value Stream Mapping 25
2. 7. Benefits of Implementing Lean . 30
2. 7. 1. Opera onal Improvements 30
2. 7. 2. Administra ve Improvements .. 30II
TABLE OF CONTENTES
2. 7. 3. Strategic Improvements 31
2. 8. Summary . 33
3. PCKAGING MANUFACTURE . 35
3. 1. Introduc on .. 35
3. 2. The Origin of Corrugator Machine .. 35
3. 3. Corrugated Fiberboard Shipping-Containers Processing and Design . 38
3. 3. 1. Corruga on geometry 40
3. 3. 2. Corruga ng medium .. 40
3. 3. 3. Liner boards . 41
3. 3. 4. Corrugated container manufacture .. 41
3. 3. 5. Adhesives .. 41
3. 3. 6. Creasing, slo ng, and die-cutting of box blanks .. 42
3. 3. 7. Common box styles . 42
4. CASE STUDY .. 44
(PACKLINE PACKAGING FACTORY) 44
4. 1. Flow chart of Produc on Management 44
4. 2. Repro House & Prepress 49
4. 3. Manpower Requirement 50
4. 4. Raw Material . 51
4. 5. Power Consump on and the Related Facili es 51
4. 6. Inspec ons and Tes ng Equipment 51
4. 7. Layout for the Package Plant .. 52
4. 8. Plant Descrip ons .. 53
4. 8. 1. Descrip on of Machinery 53
4. 8. 2. Types of raw materials for corrugated paper board 61
4. 8. 3. Types of corrugated paperboard . 62
4. 8. 4. The most important test methods for corrugated fiberboard .. 64
4. 8. 5. The most important performance test methods for corrugated boxes .. 66
4. 8. 6. Basic technical specifica?ons for the procurement of corrugated boxes .. 69
5. PROBLEM DEFINITION AND SOLVING .. 70
5. 1. Pareto Case Study .. 70III
TABLE OF CONTENTES
5. 2. Inventory Waste (cause and effect) 72
5. 3. Value Stream Mapping 74
5. 3. 1. Value Stream Mapping Icons . 75
5. 3. 2. Benefits .. 76
5. 3. 3. Steps . 76
5. 3. 4. Future Value Stream Mapping . 82
5. 4. Total Produc ve Maintenance (TPM) 88
5. 4. 1. Steps in introduc on of TPM in a organization .. 89
5. 4. 2. Advantage of applying TPM 90
5. 5. Mo on .. 90
5. 5. 1. 5-Why’s? 91
5. 5. 2. Excess-motion elimination .. 92
5. 5. 3. The current mo on . 92
5. 5. 4. Suggested mo on strategy . 97
5. 6. Setup-reduction .. 97
5. 6. 1. Why Quick Change Over? 98
5. 6. 2. The four elements of setup .100
5. 6. 3. Present setup me: ..101
5. 6. 4. Shingo’s Eight Rules ..102
5. 6. 5. Setup ?me a?er modifica?on: ..102
5. 7. Applying 5-S on Packline Company ..103
5. 7. 1. 5-S denotes to (Sort, Stabilize, Shine, Standardize and Sustain) ..103
5. 7. 2. Applica on of 5-S on Packline factory ..107
5. 8. Simula on 108
5. 8. 1. What is simulation? ..108
5. 8. 2. Modeling .109
5. 8. 3. What's being modeled? .109
5. 8. 4. Computer Simula on ..110
5. 8. 5. Simula on Model ..111
5. 8. 6. Distribu on Lists .112
5. 8. 7. The Model Flow chart .120IV
TABLE OF CONTENTES
5. 8. 8. The Variables Screen 122
5. 8. 9. Simula?on Verifica?on and Validation and Transient Period .122
5. 7. 10. Modified Arena Model: 124
5. 8. 11. The Result of Modified Model Versus the current Model: 124
6. RESULTS, CONCLUSION AND RECOMMENDATION 126
6. 1. Results 126
6. 1. 1. Excess mo on ..126
6. 1. 2. Value stream mapping 126
6.1.3 Setup Time Reduc on .127
6. 1. 4. Simula on results ..128
6. 2. Conclusions .128
6. 3. Recommenda on 130
Literature ..132
Appendix(A): Abbreviations and Acronyms 136
APPENDIX (B): SIMULATION MODEL 137
Experiment File: ..137
Model File: ..143
APPENDIX (C) SIMULATION RESULTS ..152
Current Model Result (Arena’s program sheet model) ..152
Suggested Model Result
LIST OF FIGURES
Figure 1: Withdrawal Kanban .. 13
Figure 2: Produc on Kanban 14
Figure 3: Classifica?on of Produc?on Plants .. 24
Figure 4: Value Stream Mapping Symbols .. 28
Figure 5: Old Corruga on Machines 37
Figure 6: Single Face Corrugated Board 38
Figure 7: Double Linear Corrugated Board . 39
Figure 8: Double Corrugated Board . 39
Figure 9: Triple Corrugated Board 39
Figure 10: General view of Packline Factory .. 44
Figure 11: Flow Chart of Produc on Management 48
Figure 12: Packline Manufacture Layout .. 52
Figure 13: Corrugated Line 53
Figure 14: Mill Roll Stand 54
Figure 15: Pre-heater 54
Figure 16 Glue Sta on . 55
Figure 17 Glue Packets 56
Figure 18: Four Prin ng Stages .. 59
Figure 19: Ink and Water Cleaning Cycle .. 60
Figure 20 .. 60
Figure 21: Ink Cycle 60
Figure 22: Raw Material Inventory . 61
Figure 23: Compression Test 66
Figure 24 Example of Cer?fica?on Stamp for Corrugated Boxes .. 69
Figure 25: Pareto Chart for Packline Wastes . 71
Figure 26: Cumula ve Pareto chart . 71
Figure 27: Work in process inventory . 72
Figure 28: Cause and defect diagram . 73VI
LIST OF FIGURES
Figure 29 Material flow icons .. 75
Figure 30: Informa on Flow Icons 75
Figure 33: Transport Mo on Waste 91
Figure 34: Excess-motion .. 92
Figure 35: Current mo on . 93
Figure 36: Weight of Mo on 95
Figure 37: Percentage of Each Process .. 96
Figure 38: Suggested motion strategy 97
Figure 39: Change over 98
Figure 40: Effect of Quick Change Over (QCO) . 99
Figure 41: Internal and External Setup Time . 99
Figure 42: Illustra on of 5 S’s 104
Figure 43: Sor ng .105
Figure 44: Stabilizing ..105
Figure 45: Sustaining ..106
Figure 46: the Input Analyzer Window 111
Figure 47: No of sheets in one product ..112
Figure 48: Single sheet produc on service me ..113
Figure 49: Double sheet produc on service me 114
Figure 50: Assembly service me ..115
Figure 51: moving service me 116
Figure 52: Printer 6Pa service me 117
Figure 53: Printer 8Pa service me 118
Figure 54: Printer 9Pa service me 119
Figure 55: Printer P1200 service me .120
Figure 57: Arena Variable Screens .122
Figure 58: Average Waiting Time in System 124
Figure 59: Average No. Wai ng In Printers Queue .125
Figure 60: Resources Instantaneous U liza on 125
Figure 61: Total produc on me before and a er applying the pull system .127VIII
LIST OF TABLES
LIST OF TABLES
Table 1: Corrugated Board Flute Specifica?ons and Rela?ve Proper?es . 40
Table 2: Man power requirement for Corrugators . 50
Table 3: Man power requirement for converter . 50
Table 4 .. 63
Table 5: Pareto check sheet . 70
Table 6: Summary of data in the current State map for Packline Company .. 76
Table 7: Corrugator cycle me 78
Table 8: Printers cycle me .. 78
Table 9: Times for Produc on Safety Sheets on Corrugator 84
Table 10: Forkli Distance, Transporta on and Finishing Time . 84
Table 11: forkli speed, li ing and turning me . 85
Table 12: Corrugator rate .. 85
Table 13: Shows the average number of units moved between departments . 94
Table 14: Mo on of Processes 96
Table 15: Current Setup Time ..101
Table 16: No. of Setup Time Workers ..102
Table 17: Setup Time Reduc on .103
Table 18: 5-S Check list table .
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