Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study
This study aims to address the challenge of implementing Lean philosophy in Small and Medium Enterprises (SMEs) and fill the research gap regarding Lean application in vehicle seat upholstery maintenance/repairing processes. The Lean tools applied in a case study of an upholstery industry of vehicle...
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| Format: | Article |
| Language: | English |
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MDPI AG
2023-09-01
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| Series: | Applied Sciences |
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| Online Access: | https://www.mdpi.com/2076-3417/13/17/9974 |
| _version_ | 1827728240005873664 |
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| author | Eva Santos Tânia M. Lima Pedro D. Gaspar |
| author_facet | Eva Santos Tânia M. Lima Pedro D. Gaspar |
| author_sort | Eva Santos |
| collection | DOAJ |
| description | This study aims to address the challenge of implementing Lean philosophy in Small and Medium Enterprises (SMEs) and fill the research gap regarding Lean application in vehicle seat upholstery maintenance/repairing processes. The Lean tools applied in a case study of an upholstery industry of vehicle seats were as follows: Value Stream Mapping, Spaghetti Diagram, Gemba, 5S, Standardized Work, Kaizen, Kanban, and Poka-Yoke tools. A Decision Support Method using Excel Microsoft 365 was developed for improved stock control. A GUT Matrix was formulated to prioritize improvement opportunities, aiding prompt decision-making. This systematic approach enabled the company to address critical areas requiring swift attention. The results of Lean tools implementation led to a process waste minimization around 47%, and the process Lead Time decreased by approximately 26%, resulting in a 33% production increase. Thus, the Lean tools integration leads to substantial waste reduction, shorter process time, and increased production. The Decision Support Method enabled the company to efficiently monitor and manage its stock levels, thereby enhancing inventory management practices. This case study outlines the successful optimization of an upholstery production process in an SME by effectively applying Lean tools, highlighting its feasibility and benefits. |
| first_indexed | 2024-03-10T23:26:37Z |
| format | Article |
| id | doaj.art-47a3a8b6051a454bac871160d14ed5f8 |
| institution | Directory Open Access Journal |
| issn | 2076-3417 |
| language | English |
| last_indexed | 2024-03-10T23:26:37Z |
| publishDate | 2023-09-01 |
| publisher | MDPI AG |
| record_format | Article |
| series | Applied Sciences |
| spelling | doaj.art-47a3a8b6051a454bac871160d14ed5f82023-11-19T07:54:17ZengMDPI AGApplied Sciences2076-34172023-09-011317997410.3390/app13179974Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case StudyEva Santos0Tânia M. Lima1Pedro D. Gaspar2Department of Electromechanical Engineering, University of Beira Interior, Rua Marquês de D’Ávila e Bolama, 6201-001 Covilhã, PortugalDepartment of Electromechanical Engineering, University of Beira Interior, Rua Marquês de D’Ávila e Bolama, 6201-001 Covilhã, PortugalDepartment of Electromechanical Engineering, University of Beira Interior, Rua Marquês de D’Ávila e Bolama, 6201-001 Covilhã, PortugalThis study aims to address the challenge of implementing Lean philosophy in Small and Medium Enterprises (SMEs) and fill the research gap regarding Lean application in vehicle seat upholstery maintenance/repairing processes. The Lean tools applied in a case study of an upholstery industry of vehicle seats were as follows: Value Stream Mapping, Spaghetti Diagram, Gemba, 5S, Standardized Work, Kaizen, Kanban, and Poka-Yoke tools. A Decision Support Method using Excel Microsoft 365 was developed for improved stock control. A GUT Matrix was formulated to prioritize improvement opportunities, aiding prompt decision-making. This systematic approach enabled the company to address critical areas requiring swift attention. The results of Lean tools implementation led to a process waste minimization around 47%, and the process Lead Time decreased by approximately 26%, resulting in a 33% production increase. Thus, the Lean tools integration leads to substantial waste reduction, shorter process time, and increased production. The Decision Support Method enabled the company to efficiently monitor and manage its stock levels, thereby enhancing inventory management practices. This case study outlines the successful optimization of an upholstery production process in an SME by effectively applying Lean tools, highlighting its feasibility and benefits.https://www.mdpi.com/2076-3417/13/17/9974value stream mappingspaghetti diagram5Sstandardized workKaizenKanban |
| spellingShingle | Eva Santos Tânia M. Lima Pedro D. Gaspar Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study Applied Sciences value stream mapping spaghetti diagram 5S standardized work Kaizen Kanban |
| title | Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
| title_full | Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
| title_fullStr | Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
| title_full_unstemmed | Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
| title_short | Optimization of the Production Management of an Upholstery Manufacturing Process Using Lean Tools: A Case Study |
| title_sort | optimization of the production management of an upholstery manufacturing process using lean tools a case study |
| topic | value stream mapping spaghetti diagram 5S standardized work Kaizen Kanban |
| url | https://www.mdpi.com/2076-3417/13/17/9974 |
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