Dexter G.

Avejero

BSCpE 3201

Reducing Waste in Production by Lean Thinking - A Case study

Gap/Problem

The challenge of balancing high production rates with maintaining the desired quality of
products in a competitive industrial environment. This problem is highly prevalent in the
manufacturing and production sectors, and it results from a number of interrelated such as:

 Overproduction
 Inventory Complexity
 Defects
1. Excess machining stock on the top window
2. Machine spindle perpendicularity is not ok
 Overprocessing
 Waiting
 Poor People/ Machineries
 Transportation

Methods

The elimination of waste represents a huge potential in terms of manufacturing

improvements:

1. Identify both waste and value

2. Develop our knowledge management base

3. Realize that sustainable improvement requires the buy in of the people operating the processes
and managing the business, and therefore a culture of continuous improvement.

As stated in the case study, there are various tools of the lean processing that can be used
in order to eliminate wastes at most instance. One method discussed in the paper is the Poka-
Yoke. It is a Japanese word which means removing error or error proofing. It is a strategy to
eliminate waste and enhance quality in manufacturing. It focuses on preventing errors at their
source to avoid defects. Poka-yoke uses devices or methods to either prevent errors or quickly
detect them. This approach reduces waste by minimizing defective products, rework, and scrap,
leading to improved quality and efficiency in manufacturing. It's a powerful tool for achieving
zero defects and continuous improvement. Given below are the methods alongside with Lean
thinking used:

1. Identify the problem

2. Taking the observation on the problem
3. Finding the root cause of the problem
4. Fining the solution on the problem
5. Implement the solution
6. Continuous monitor and sign off

Results
The study successfully identified the root causes of defects in the manufacturing process,
specifically related to the machining of clutch housing components. The two main causes were
excess machining stock on the top window and machine spindle perpendicularity issues.
Hypothesis testing was conducted to validate these identified root causes, confirming that excess
machining stock and spindle perpendicularity disturbances were indeed responsible for defects in
the machining process. Effective remedial actions were proposed and implemented to address
these root causes, including providing feedback to the foundry section to check machining stock
and restoring machine spindle perpendicularity to the required level.

After implementing these solutions, a re-evaluation of the machining process

demonstrated significant improvements in product quality. The flatness of the machined
components now met the customer's specifications, marking a substantial enhancement in overall
product quality. To sustain and continuously improve product quality while reducing defects, the
case study recommended various measures. These included increasing the frequency of patrol
checks for flatness, conducting more frequent checks of machine spindle perpendicularity, and
providing training to maintenance personnel.

Conclusion
 The study highlighted the effectiveness of Lean Thinking and Poka-Yoke techniques in
reducing errors and defects in manufacturing. The most notable result was a significant drop in
the rejection rate. Initially at 17% per lot of a hundred units, this high rejection rate caused
financial losses and customer dissatisfaction. However, by applying Lean Thinking principles
and Poka-Yoke methods, the company addressed root causes, resulting in a minimum rejection
rate. This not only led to cost savings but also improved customer satisfaction, illustrating how
these methodologies can drive positive change in manufacturing.

The results of the study were compelling. It successfully pinpointed the root causes of
defects in the machining of clutch housing components, specifically excess machining stock and
machine spindle perpendicularity issues. Through hypothesis testing, these causes were
validated, and effective remedial actions were proposed and implemented. Subsequently, product
quality substantially improved, meeting customer specifications and significantly reducing
rejection rates.

Your Conclusion

In conclusion, the case study focused on addressing the pressing challenge of balancing
high production rates with maintaining product quality in a fiercely competitive industrial
landscape. It identified several key issues contributing to waste in production, such as
overproduction, inventory complexity, defects, overprocessing, waiting, poor equipment, and
transportation inefficiencies. To combat these problems, the study employed Lean Thinking
principles, emphasizing the need to identify both waste and value, develop knowledge
management capabilities, and foster a culture of continuous improvement among the workforce.

One pivotal methodology discussed in the case study was Poka-Yoke, a Japanese
approach aimed at error prevention and elimination. By proactively addressing errors at their
source and implementing error-proofing techniques, Poka-Yoke significantly reduced waste,
minimized defective products, and enhanced manufacturing efficiency and product quality. The
process of identifying problems, observing them, finding their root causes, devising solutions,
implementing changes, and continuously monitoring progress played a crucial role in achieving
these improvements.