In the last decades, competition between several industries to deliver high-quality
products is marginally increasing in terms of costs and performance. Lean is one of
those activities that focuses on reducing costs by eliminating non-value-added
activities. This factory faces various wastes in its production process, including
defects, waiting, unnecessary inventory, overprocessing, unnecessary motion,
overproduction, and transportation. This study uses a lean manufacturing
approach, Value Stream Mapping, to identify and minimize waste, enhance
production time efficiency. Meanwhile, green manufacturing is an approach that
seeks to achieve measurable and significant environmental improvements. In this
research, we study the causal relationship between lean and green manufacturing.
We apply several lean tools to enhance the efficiency of a mixed-product production
line used in vehicle assembly. A future state VSM incorporating Kanban pull
systems, supermarket buffers, and 5S workplace organization was developed and
validated. Through the study, we found out that lean and green have a strong
relationship in terms of waste elimination, resource efficiency, and environmental
impact reduction, where the implementation of lean tools simultaneously achieves
both operational excellence and sustainability objectives. Quantitative results
demonstrate a lead time reduction from 178.453 to 15.883 days (a 91.099%
decrease). These percentages have a direct effect on the flow of materials and
information, save raw materials for other uses, free up people to work on other
products, and change the amount of electricity used, the amount of water used in
cooling systems for injection processes, and the amount of inventory in
warehouses. In the end, they affect the percentage of defective products. |
