Wastes

Abstract: Lean Thinking is a highly evolved method of managing an organization to improve the productivity, efficiency and quality of its products or services. The core principle it uses is that no work should be done unless it is going to create customer value.

Manufacturers always face cost-reduction and efficiency challenges in their operations. Industries require improvement  in  Production  Lead  Times,  costs  and  customer  service  levels  to  survive.  Because  of  this, companies  have  become  more  customers  focused.  The  result  is  that  companies  have  been  putting  in significant effort to improve their efficiency.

In  this  paper  Value  Stream  Mapping  (VSM)  tool  is  used  in  bearing  manufacturing  industry  by  focusing both on processes and their cycle times for a product UC- 208 INNER which is used in plumber block. Inorder to use the value stream mapping, relevant data has been collected and analyzed. After collecting the data  customer  need  was  identified.  Current  state  map  was  draw  by  defining  the  resources  and  activitiesneeded  to  manufacture,  deliver  the  product.  The  study  of  current  state  map  shows  the  areas  for improvement  and  identifying  the  different  types  of wastes.  From  the  current  state  map,  it  was  noticeable that Annealing and CNC Machining processing have higher cycle time and work in process.

The  lean  principles  and  techniques  implemented  or  s
uggested  and  future  state  map  was  created  and  the
total  lead  time  was  reduced  from  7.3  days  to  3.8  da
ys.  The  WIP  at  each  work  station  has  also  been
reduced. The production lead time was reduced from
409 seconds to 344 seconds.

Biodiesel is an alternative diesel fuel produced using transesterification method where edible or non edible oil and alcohol reacts in the presence of catalyst. Biodiesel is expensive than fossil fuels because of higher raw material and production costs. Solid coconut waste is an alternative raw material from waste and suitable for biodiesel production to lower the production cost. Solid coconut waste is produced after coconut milk extraction and may still contain 17–24 wt% extractable oil content. This study introduces reactive extraction of solid coconut waste for biodiesel production. Effects of catalyst amount, KOH (0.8–2.0%), temperature (55–65 °C) and mixing intensity (500–900 rpm) were studied to optimize the reactive extraction. Based on the Response Surface Methodology (RSM), the optimum condition was found to be 2.0 wt% of KOH catalyst, 700 rpm of mixing intensity and reaction temperature, 62 °C where resulted in 88.5% of biodiesel yield.

http://www.sciencedirect.com/science/article/pii/S1876107012001678

In order to improve the properties of asphalt mixture and reduce the negative impact of the waste materials on nature and the environment, it seems to be logical to propose a means of re-using waste materials in engineering and industrial construction projects such as road pavement. The current paper presents an experimental research on the application of waste plastic bottles (Polyethylene Terephthalate (PET)) as an additive in stone mastic asphalt (SMA). Wheel tracking, moisture susceptibility, resilient modulus and drain down tests were carried out on the mixtures that included various percentages of waste PET as 0%, 2%, 4%, 6%, 8% and 10% by weight of bitumen content. By experimentation, the appropriate range for the amount of waste PET was determined to be 4-6% by weight of the bitumen content. The results show that the addition of waste PET into the mixture has a significant positive effect on the properties of SMA which could improve the mixture's resistance against permanent deformation (rutting), increase the stiffness of the mix, provide lower binder drain down and promotion of re-use and recycling of waste materials in a more environmentally and economical way. © 2012 Elsevier Ltd. All rights reserved.

http://www.sciencedirect.com/science/article/pii/S0950061812004072

Manufacturers always face cost-reduction and efficiency challenges in their operations. Industries require improvement  in  Production  Lead  Times,  costs  and  customer  service  levels  to  survive.  Because  of  this,
companies  have  become  more  customers  focused.  The  result  is  that  companies  have  been  putting  in significant effort to improve their efficiency.

In  this  paper  Value  Stream  Mapping  (VSM)  tool  is  used  in  bearing  manufacturing  industry  by  focusing both on processes and their cycle times for a product UC- 208 INNER which is used in plumber block. In order to use the value stream mapping, relevant data has been collected and analyzed. After ollecting the data  customer  need  was  identified.  Current  state  map  was  draw  by  defining  the  resources  and  activities needed  to  manufacture,  deliver  the  product.  The  study  of  current  state  map  shows  the  areas  for improvement  and  identifying  the  different  types  of wastes.  From  the  current  state  map,  it  was  noticeable that Annealing and CNC Machining processing have higher cycle time and work in process.

The  lean  principles  and  techniques  implemented  or  suggested  and  future  state  map  was  created  and  the
total  lead  time  was  reduced  from  7.3  days  to  3.8  days.  The  WIP  at  each  work  station  has  also  been reduced. The production lead time was reduced from 409 seconds to 344 seconds.

This work presents an experimental study of the effect of addition of wood waste, especially Wood shavings (WS) and sawdust (S), on the thermal properties using the box method. The results obtained show a significant decrease in density and thermal conductivity λ (W/m°C) with an increase in the content of wood waste.

The purpose of this study is to develop a plan for reducing lead-times and increasing profit of Centre bolt product by using value stream mapping. The Centre bolt product manufacturer is inefficient because it produces products in large batch quantities and has poor product flow as operations being departmentalized and departments are very far away from each other due to this increase in lead-times could cause a loss in the market share to its competitors. The Centre bolt product manufacturer must reduce its lead-times in order to remain competitive and continue its growth by providing quality products in a timely manner. A study will be carried out using value stream mapping to determine areas of potential improvement on the plant floor. A current state map will be developed and analyzed the areas that have potential for improvement. A future state map will then be created to suggest ways to reduce lead-times and increase profit. The map will include lean manufacturing methods to r...

This paper focuses on the application of Taguchi Robust Design to Lean Production System to analyse Industrial production wastes. The purpose of this study is to present robust design approach that reduces and possibly eliminate losses to the society that arise due to variations leading to wastes in production processes. Past literatures were reviewed and applied to case study Innoson Vehicle Manufacturing Company (IVM) for the purpose of this study. The application of the Taguchi robust design approach to IVM motor production processes revealed that over-production, excess inventory, defects, and over-processing are the major wastes that are impeding their progress and profitability. The successful application of Taguchi robust design using Design Expert software to analyse two production periods produced varying results, and also revealed Overproduction and Excess inventory as the highest forms of wastes in the firm. In IVM’s first three months of production, over-production had t...