Integration of lean manufacturing and value engineering techniques to improve the internal distribution system in a manufacturing company

The XYZ Corporation is located in Lafayette, Georgia. The company produces cooking ranges for the North American market. It has 1500 employees with a daily production capacity of 1000 to 1500 cooking ranges. The company is implementing lean manufacturing techniques to improve their performance. One of their projects is to develop a distribution system, which will help in streamlining the internal distribution of Very High Pressure (VHP) adhesive tapes. The aim of this research is to develop a lean distribution system by applying techniques of lean manufacturing systems. To understand the existing process of distribution, a flow diagram was created. Waste or non value added functions were identified by applying the Functional Analysis System Technique (FAST) diagram, which is a tool used in value engineering or value analysis projects. The existing process is identified with three kinds of waste: waiting, unnecessary motion, and overproduction. Waiting and unnecessary motions were eliminated from the receiving process using the concepts of the set theory, a tool used in systems engineering. At the same time, over production in assembly lines was not eliminated due to unknown reasons. The research further applies a concept from systems thinking called tragedy of commons, to identify the root causes of over production in the existing process. Based on the results, the necessary recommendations are provided to restructure the management system at the production floor or assembly level of the organization. This will allow the line operators to understand the benefits of having low cost manufacturing for their survival in this competitive world.

Grantor dc:publisher

University of Tennessee at Chattanooga

Author dc:creator

• Prahladaraj, Sripadjaraj

Contributors dc:contributor

• Alp, Neslihan
• McMahon, Edward H.; Gibson, Barry
• College of Engineering and Computer Science

• Lean Manufacturing
• Value analysis (Cost control)

Licence

• https://rightsstatements.org/page/InC/1.0/?language=en

Language dc:language

English, eng

Identifier

LB2369.2 .P723 2004

OAI identifier oai:identifier

oai:scholar.utc.edu:theses-1768