Coventry University

School of Engineering

PEPs

MSc Dissertation in
Engineering Business Management

Implementation of
Lean Manufacturing
System

Submitted By: Haitem Fargani

Project Supervisor: Richard Dufill

26th August 2005
 Contents

1. Introduction

2. Literature Review

3. Lean Manufacturing Tools and Techniques

4. Case Study

5. Just-In-Time Delivery Vs Transportation

Costs

6. Supplier and Customer Integration

7. Change Management

8. Concluosion
 Research Objectives

 Identify the main tools and techniques in “lean

production” that are used on the shop-floor.

 Highlight the importance of supply chain

integration.

 Show the benefits that can be gained from

adopting lean manufacturing.

 Investigate the right procedure to change from

“mass production” to “lean production”.

 Demonstrate with a case study that a company

can choose from lean tools what is useful for it
and leave what is not useful if the application
proved to be inappropriate.
 Case Study

Visteon Sistemas Automotivos (Brazil)

Primary Secondary Coil Epoxy Final

Coil Coil Assembly Encapsulation Test
Winding Winding

Material Entry Final Product

(Ignition Coil)

 Lean Techniques Used:

1. Cellular Layout
2. One-piece-flow
3. Manual vs. Automated (simplify)
  Achievements:

1. 27% Investment Reduction

2. 60% Floor-Sspace Reduction
3. 17% Direct Labour Reduction

 Choosing the Case Study:

1. Shows the benefits of applying lean

manufacturing.
2. Explains how to use lean tools.
3. It shows that some tools might not be
practical to use in some cases.

 The first is in the primary coil winding where one-piece-flow was

not used due to the need of using a multiple-spindle winder to
meet required cycle time. It was unreasonable in terms of
investment, floor space and labour to replace the multiple-spindle
winder with multiple single spindle winders.
 The second instance is in the epoxy encapsulation station where
manual handling of parts was not possible, due to safety reason,
which limited the opportunities for using lean concepts.
 Just-In-Time Delivery Vs.
Transportation Costs

Inventory Transportation
Levels Costs

 Factors:
Supplier geometry
Supplier time window
The number of suppliers

Chuah and Yingling (2001)

 Change Management

 Introduction to Change Management

 Resistance to Change
 Approach to Change
 Shop-floor Rearrangement
 Application order of lean tools

Conclusion

 Evaluate tools before using them

Thank You All