Implementation of lean through development of alternative manufacturing process using simulation model Case study at kangaroo shoe factory

Abstract

This Research Is Crafted With An Intention To Implement Lean Manufacturing System On Footwear Industry In Kangaroo Shoe Factory To Improve Its Manufacturing System. The System Improvement Will Be Supported By Two Tools Selected From Lean Packages. All Presently Occurring Production That Are Necessary For The Selected Style Of Footwear Product (The Physical And Information Flow) Will Be Mapped And Analyzed To Identify The Waste There By Provide Improvement Suggestion For The Construction Of Newly Modified Map With New Flow. The Main Input Data That Are Encoded To Arena Software Includes Activity Description, Identified Type Of Activity, Process Observation Time And Number Of Workers. The Vsm Current Status Map Output Will Be Simulated Using Arena Software And Depicted Quantitatively In The Form Expected Result With Tabulated Explanation. The Simulation Result Includes The Amount Of, The Total Number Of Wip, Simulation Time Interval, Number Of Product In, Va And Nva Time Per Entity, Total Time Per Entity, Accumulated Nva Time And Accumulated Waiting Time Based On As-Is Manufacturing System. This Result Is Verified Comparing With Actual Production. The Section Wise Average Error Encountered Are 0.008% In Preparation, 0.056 % In Stitching Section And 0.032% In Lasting And Finishing. After Application Of Lean Improvement To The Current Production System (I.E.; Application Of Vsm And Bottleneck Analysis), The Modified Production System Is Mapped And The Newly Modified Type Of Input Data Have Been Encoded To Arena Software And Finally Simulated Using Arena To Result The Tobe Manufacturing System Incorporated With Improvement Option. And This Newly Developed Manufacturing System (Opportunity For Further Improvement) Proposed To Kangaroo Shoe Factory With Main Changes Such As; 3.125% Final Production Output Increment In Lasting And Finishing Section, (5.88 ) % Wip Reduction. In Stitching, 32.5% And 41.1% Total Processing Time Reduction In Stitching And Preparation Section Respectively.