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Implementing lean standard work to solve a low work-in-process buffer problem in a highly automated manufacturing environment

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  • Jiunn-Chenn Lu
  • Taho Yang

Abstract

Over the past few decades, a considerable number of studies have been reported on assembly lines or less automated factories. Little attention has been given to implementing lean tools to a highly automated manufacturing environment. It is, therefore, necessary to make a more highly automated factory lean by considering both the manufacturing system variability and demand uncertainty. The purpose of this paper is to propose an effective lean tool to help practical lean participants successfully implement lean practices in a highly automated manufacturing environment. This study presents an example of how lean standard work is implemented and the throughput of a pacemaker workstation is improved by solving the low work-in-process buffer problem. A practical case from a photovoltaic module process with a semi-automated production line is used to illustrate the proposed method. The implementation results are promising. They showed a 37.5% labour reduction prior to the pacemaker workstation and a 304.7% increase in the daily throughput at the bottleneck workstation.

Suggested Citation

  • Jiunn-Chenn Lu & Taho Yang, 2015. "Implementing lean standard work to solve a low work-in-process buffer problem in a highly automated manufacturing environment," International Journal of Production Research, Taylor & Francis Journals, vol. 53(8), pages 2285-2305, April.
  • Handle: RePEc:taf:tprsxx:v:53:y:2015:i:8:p:2285-2305
    DOI: 10.1080/00207543.2014.937009
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    Citations

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    Cited by:

    1. Emil Ratter & Stanislaw Nader, 2022. "The Use of Lean Management Tools in Production Companies with Implemented Total Quality Management (TQM)," European Research Studies Journal, European Research Studies Journal, vol. 0(3), pages 357-368.
    2. José Carlos Sá & Manuel Reis & José Dinis-Carvalho & Francisco J. G. Silva & Gilberto Santos & Luis P. Ferreira & Vanda Lima, 2022. "The Development of an Excellence Model Integrating the Shingo Model and Sustainability," Sustainability, MDPI, vol. 14(15), pages 1-28, August.
    3. Aqlan, Faisal & Al-Fandi, Lawrence, 2018. "Prioritizing process improvement initiatives in manufacturing environments," International Journal of Production Economics, Elsevier, vol. 196(C), pages 261-268.

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