Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study
Autor(a) principal: | |
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Data de Publicação: | 2023 |
Outros Autores: | , |
Tipo de documento: | Artigo |
Idioma: | eng |
Título da fonte: | Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) |
Texto Completo: | http://hdl.handle.net/10400.6/14114 |
Resumo: | This study aims to address the challenge of implementing Lean philosophy in Small and Medium Enterprises (SMEs) and fill the research gap regarding Lean application in vehicle seat upholstery maintenance/repairing processes. The Lean tools applied in a case study of an upholstery industry of vehicle seats were as follows: Value Stream Mapping, Spaghetti Diagram, Gemba, 5S, Standardized Work, Kaizen, Kanban, and Poka-Yoke tools. A Decision Support Method using Excel Microsoft 365 was developed for improved stock control. A GUT Matrix was formulated to prioritize improvement opportunities, aiding prompt decision-making. This systematic approach enabled the company to address critical areas requiring swift attention. The results of Lean tools implementation led to a process waste minimization around 47%, and the process Lead Time decreased by approximately 26%, resulting in a 33% production increase. Thus, the Lean tools integration leads to substantial waste reduction, shorter process time, and increased production. The Decision Support Method enabled the company to efficiently monitor and manage its stock levels, thereby enhancing inventory management practices. This case study outlines the successful optimization of an upholstery production process in an SME by effectively applying Lean tools, highlighting its feasibility and benefits. |
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Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case StudyValue stream mappingSpaghetti diagram5SStandardized workKaizenKanbanPoka-YokeDecision support systemUpholsterySmall and medium enterprisesThis study aims to address the challenge of implementing Lean philosophy in Small and Medium Enterprises (SMEs) and fill the research gap regarding Lean application in vehicle seat upholstery maintenance/repairing processes. The Lean tools applied in a case study of an upholstery industry of vehicle seats were as follows: Value Stream Mapping, Spaghetti Diagram, Gemba, 5S, Standardized Work, Kaizen, Kanban, and Poka-Yoke tools. A Decision Support Method using Excel Microsoft 365 was developed for improved stock control. A GUT Matrix was formulated to prioritize improvement opportunities, aiding prompt decision-making. This systematic approach enabled the company to address critical areas requiring swift attention. The results of Lean tools implementation led to a process waste minimization around 47%, and the process Lead Time decreased by approximately 26%, resulting in a 33% production increase. Thus, the Lean tools integration leads to substantial waste reduction, shorter process time, and increased production. The Decision Support Method enabled the company to efficiently monitor and manage its stock levels, thereby enhancing inventory management practices. This case study outlines the successful optimization of an upholstery production process in an SME by effectively applying Lean tools, highlighting its feasibility and benefits.Applied SciencesuBibliorumSantos, Eva Maria VitorinoLima, Tânia M.Gaspar, Pedro Dinis2024-01-23T11:56:20Z20232023-01-01T00:00:00Zinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/articleapplication/pdfhttp://hdl.handle.net/10400.6/14114engSantos, E.; Lima, T.M.; Gaspar, P.D. Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study. Appl. Sci. 2023, 13, 9974. https:// doi.org/10.3390/app131799742076-341710.3390/app13179974info:eu-repo/semantics/openAccessreponame:Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos)instname:Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãoinstacron:RCAAP2024-01-24T04:57:32Zoai:ubibliorum.ubi.pt:10400.6/14114Portal AgregadorONGhttps://www.rcaap.pt/oai/openaireopendoar:71602024-03-20T01:56:54.621588Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informaçãofalse |
dc.title.none.fl_str_mv |
Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
title |
Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
spellingShingle |
Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study Santos, Eva Maria Vitorino Value stream mapping Spaghetti diagram 5S Standardized work Kaizen Kanban Poka-Yoke Decision support system Upholstery Small and medium enterprises |
title_short |
Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
title_full |
Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
title_fullStr |
Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
title_full_unstemmed |
Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
title_sort |
Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
author |
Santos, Eva Maria Vitorino |
author_facet |
Santos, Eva Maria Vitorino Lima, Tânia M. Gaspar, Pedro Dinis |
author_role |
author |
author2 |
Lima, Tânia M. Gaspar, Pedro Dinis |
author2_role |
author author |
dc.contributor.none.fl_str_mv |
uBibliorum |
dc.contributor.author.fl_str_mv |
Santos, Eva Maria Vitorino Lima, Tânia M. Gaspar, Pedro Dinis |
dc.subject.por.fl_str_mv |
Value stream mapping Spaghetti diagram 5S Standardized work Kaizen Kanban Poka-Yoke Decision support system Upholstery Small and medium enterprises |
topic |
Value stream mapping Spaghetti diagram 5S Standardized work Kaizen Kanban Poka-Yoke Decision support system Upholstery Small and medium enterprises |
description |
This study aims to address the challenge of implementing Lean philosophy in Small and Medium Enterprises (SMEs) and fill the research gap regarding Lean application in vehicle seat upholstery maintenance/repairing processes. The Lean tools applied in a case study of an upholstery industry of vehicle seats were as follows: Value Stream Mapping, Spaghetti Diagram, Gemba, 5S, Standardized Work, Kaizen, Kanban, and Poka-Yoke tools. A Decision Support Method using Excel Microsoft 365 was developed for improved stock control. A GUT Matrix was formulated to prioritize improvement opportunities, aiding prompt decision-making. This systematic approach enabled the company to address critical areas requiring swift attention. The results of Lean tools implementation led to a process waste minimization around 47%, and the process Lead Time decreased by approximately 26%, resulting in a 33% production increase. Thus, the Lean tools integration leads to substantial waste reduction, shorter process time, and increased production. The Decision Support Method enabled the company to efficiently monitor and manage its stock levels, thereby enhancing inventory management practices. This case study outlines the successful optimization of an upholstery production process in an SME by effectively applying Lean tools, highlighting its feasibility and benefits. |
publishDate |
2023 |
dc.date.none.fl_str_mv |
2023 2023-01-01T00:00:00Z 2024-01-23T11:56:20Z |
dc.type.status.fl_str_mv |
info:eu-repo/semantics/publishedVersion |
dc.type.driver.fl_str_mv |
info:eu-repo/semantics/article |
format |
article |
status_str |
publishedVersion |
dc.identifier.uri.fl_str_mv |
http://hdl.handle.net/10400.6/14114 |
url |
http://hdl.handle.net/10400.6/14114 |
dc.language.iso.fl_str_mv |
eng |
language |
eng |
dc.relation.none.fl_str_mv |
Santos, E.; Lima, T.M.; Gaspar, P.D. Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study. Appl. Sci. 2023, 13, 9974. https:// doi.org/10.3390/app13179974 2076-3417 10.3390/app13179974 |
dc.rights.driver.fl_str_mv |
info:eu-repo/semantics/openAccess |
eu_rights_str_mv |
openAccess |
dc.format.none.fl_str_mv |
application/pdf |
dc.publisher.none.fl_str_mv |
Applied Sciences |
publisher.none.fl_str_mv |
Applied Sciences |
dc.source.none.fl_str_mv |
reponame:Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) instname:Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informação instacron:RCAAP |
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Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informação |
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RCAAP |
institution |
RCAAP |
reponame_str |
Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) |
collection |
Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) |
repository.name.fl_str_mv |
Repositório Científico de Acesso Aberto de Portugal (Repositórios Cientìficos) - Agência para a Sociedade do Conhecimento (UMIC) - FCT - Sociedade da Informação |
repository.mail.fl_str_mv |
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1799137056896581632 |