Proposals for Improvement

Welcome back to Lean Insights Hub, where we explore practical strategies and insights into lean manufacturing and industrial management. In this article, we examine Chapter 5 of my dissertation, which presents a series of improvement proposals for company's production system based on identified inefficiencies. These proposals are designed to optimize processes, reduce waste, and enhance overall productivity.

Action Plan Framework: 5W2H

Chapter 5 employs the 5W2H method to structure the action plan for improvements. The 5W2H method is a problem-solving approach that stands for:

• What: The actions to be taken.
• Why: The reason for these actions.
• Where: The location where the actions will be implemented.
• When: The timeline for implementation.
• Who: The individuals responsible for each action.
• How: The method of execution.
• How Much: The cost or resources required.

Key Improvement Proposals

1. Registration and Study of Mesh Breakdowns, Defects, and Complaints

• What: Implement a system to record and analyze data on mesh breakdowns, product defects, and customer complaints.
• Why: To identify root causes and trends, facilitating targeted improvements.
• Where: Across all relevant production stages.
• When: Immediately and ongoing.
• Who: Quality control and production management teams.
• How: Using digital tracking tools and regular reporting.
• How Much: Initial investment in software and training, with ongoing minimal costs.

2. Introduction of Production Planning

• What: Develop a comprehensive production planning system.
• Why: To streamline workflow and reduce lead times.
• Where: Company-wide, with a focus on critical production stages.
• When: Within the next quarter.
• Who: Production planners and operations managers.
• How: Using advanced planning software and lean scheduling techniques.
• How Much: Moderate investment in planning software and training.

3. Implementation of Daily Kaizen

• What: Establish a daily continuous improvement practice (Kaizen).
• Why: To foster a culture of continuous improvement and employee engagement.
• Where: In all production departments.
• When: Immediately and ongoing.
• Who: All employees, led by team leaders.
• How: Through daily briefings, suggestion schemes, and regular review meetings.
• How Much: Minimal cost, mainly time investment.

4. Inclusion of Visual Management and 5S Program

• What: Adopt visual management tools and the 5S organizational methodology (Sort, Set in order, Shine, Standardize, Sustain).
• Why: To improve workplace organization, safety, and efficiency.
• Where: Throughout the production floor and administrative areas.
• When: Over the next six months.
• Who: All employees, guided by lean facilitators.
• How: Implementing visual aids, organizing workspaces, and regular 5S audits.
• How Much: Low to moderate cost, primarily for materials and training.

5. Application of Total Productive Maintenance (TPM)

• What: Implement TPM practices to ensure machinery is well-maintained and operates efficiently.
• Why: To reduce downtime and improve equipment effectiveness.
• Where: In areas with high equipment usage.
• When: Within the next six months.
• Who: Maintenance teams and machine operators.
• How: Regular maintenance schedules, operator training, and TPM workshops.
• How Much: Moderate investment in maintenance tools and training.

6. Implementation of a Mesh Humidification System

• What: Install a system to control the humidity of the mesh.
• Why: To reduce mesh breakdowns and improve product quality.
• Where: In the textile printing section.
• When: Over the next three months.
• Who: Engineering and maintenance teams.
• How: Installing humidification equipment and integrating it into existing systems.
• How Much: Significant initial investment with ongoing maintenance costs.

7. Installation of Cameras in Textile Printing Rotary Machines

• What: Equip rotary printing machines with cameras for monitoring.
• Why: To enhance quality control and ensure operational safety.
• Where: In the textile printing section.
• When: Over the next two months.
• Who: IT and production teams.
• How: Installing cameras and setting up monitoring systems.
• How Much: Moderate cost for equipment and setup.

Expected Outcomes

The proposed improvements aim to achieve the following outcomes:

• Reduction in Waiting Times: By 18%, through better planning and process streamlining.
• Shortened Lead Times: By 16%, via more efficient workflows and production scheduling.
• Decrease in Complaints and Nonconformities: Complaints reduced by 40%, and nonconformities by 62%, through improved quality control and feedback mechanisms.
• Enhanced Productivity and Flexibility: Through the adoption of lean methodologies and continuous improvement practices.
• Increased Employee Morale and Safety: By fostering a culture of involvement and ensuring a safer working environment.
• Monetary Gains: Estimated annual savings between €680,891 and €702,095, with a return on investment (ROI) within 7 to 8 months.

Conclusion

Chapter 5 of my dissertation offers a comprehensive action plan to address inefficiencies in company's production system. By leveraging lean tools and methodologies, these proposals aim to significantly enhance operational efficiency, product quality, and employee engagement. At Lean Insights Hub, we believe that such structured and well-thought-out improvements are crucial for driving continuous improvement and achieving long-term success in the industrial sector.

Stay tuned for our next article, where we will discuss the potential impacts of these improvements and evaluate their effectiveness.