All,
Any papers or practical experience on foundry specific lean implementations.
Thanks in advance.
Dear Martin,
the following papers will provide you with more details.
Have a nice day :-)
An empirical study on applicability of lean and green practices in the foundry industry
Prasad, S., Khanduja, D., Sharma, S.K.2016
Journal of Manufacturing Technology Management
27(3), pp. 408-426
The following paper looks at the literature in order to investigate the relationship between lean and green management and their relationship to one another while keeping in mind their simultaneous implementation at a foundry SME.
Synergizing lean and green for continuous improvement
Wadhwa, R.S.2014 Transactions of the North American Manufacturing Research Institution of SME
42(January), pp. 71-80
Daniel,
Thanks very much for your suggestions.
Much appreciated.
Martin
Everything is possible if they allocating fund for the lean implementation in traditional foundry.
For ex: 1. VSM - finding the waste (non-value added activities)
2. facilities layout change
3. Cellular approach (grouping parts)
4. 5S (universal applied - housekeeping)
5. Visual Identification
6. SOP
7. Quick set up time
8. Apply to semi automation ending with fully automation
9. Load leveling to employees
10. Improve the workplace environment for the employees
Hi Vadivel,
Thank you for contributing to the topic.
Do you have any papers or any specific case studies from your own experience, related to the 10 topics listed above?
Best Regards
Martin
Actually its SME where actual ground level work needs to be done, some are indexed as below
- SME uses equipment, full of there potential without carrying for maintainence checks. Some application can be explored here.
- SME have not well planned layouts, routing and process definition for the operation being carried out. Lean Manufacturing can be implemented there.
- SMEs face poor flexibility in terms of operation, process and labour actvities.Lean approach can flip darker side here.
- SME faces productivity issues which hamper there sustainability and growth lean application can be boom here
Lean manufacturing means reduction of un-necessary inventory present in the SMEs.
Lean has advanced beyond the use of any specific tool. It now encompasses a variety of management principles covering HR, IT, Best work practices and many others- anything that involves continuous improvement towards perfection and elimination of non-value added behaviours.
Meanwhile, unless you have a specific problem area that you want to address e.g. machine breakdowns, then you would need a specific lean toolset e.g. TPM. And you need to match this with an appropriate lean audit
Some related works you may want to check
Rodrigues, L.L., Shetty, D.K., Hebbar, S. and Hoskote, R.N., 2013, July. Performance Improvement of Foundry through Lean Methodology: A Modelling & Simulation Approach. In Modelling Symposium (AMS), 2013 7th Asia (pp. 193-198). IEEE.
Sarkar, B. (2007), “Capability enhancement of a metal casting process in a small steel foundry through six sigma: a case study”, International Journal of Six Sigma and Competitive Advantage, Vol. 3 No. 1, pp. 56-71.
Carannante, T. (1995), “TPM implementation – UK foundry industry”, The Foundryman Supplement, Vol. 88 No. 11, pp. 1-34.
Torielli, R., Abrahams, R., Smillie, R. and Voigt, R. (2011), “Using lean methodologies for economically and environmentally sustainable foundries”, China Foundry, Vol. 8 No. 1, pp. 74-88.
Jit Singh, B. and Khanduja, D., 2009. SMED: for quick changeovers in foundry SMEs. International Journal of Productivity and Performance Management, 59(1), pp.98-116.
Oliveira, C. S. D., and E. B. Pinto. 2008. “Lean Manufacturing Paradigm in the Foundry Industry.” Estudos Tecnológicos4 (3): 218–230.
Bikram Jit SinghNational Institute of Technology, Kurukshetra, India Dinesh KhandujaNational Institute of Technology, Kurukshetra, India. 2009. SMED: for quick changeovers in foundry SMEs. International Journal of Productivity and Performance Management 59:1, 98-116
1) Visual Scheduling
From my Practical Experience in both Foundries and Heat Treating in the aerospace industry, the best lead time improvement project was a visual production scheduling.
A space was dedicated, ideally directly across from the forging hammer/press or furnace, where a box was painted on the ground to show the next job waiting for the equipment in question (hammer/press or furnace). This solution has basically $0.00 cost to implement, which is ideal for resource constrained SMEs.
In the case of each furnace, this painted replica matched the dimensions of the 'working zone" of the furnace. In one corner, away from the actual furnace, a heavy duty pole was inserted into the ground and extended to the height of the working zone. Thus, all jobs were known to fit the working zone prior to loading the furnace.
The waste of waiting while the next production order was located or staged was eliminated. The visual nature of this solution made certain every employee knew what orders where to be processed next for each and every piece of equipment in the foundry.
2) Changeovers / SMED - video tape
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