Implementing Lean Tools to Improve a Production Line in a Given Company

Abstract:

In the competitive landscape of today's automotive industry, achieving excellence is fundamental. Our paper delves into the practical application of lean manufacturing principles within a given company.Drawing on collaborative efforts with industry experts and professionals, this paper documents practical experiences gained in the field of production management. By implementing various lean tools on one of the production lines in the company, significant strides were taken towards continuous improvement, resulting in enhanced productivity, reduced lead times, and heightened customer satisfaction.The study focuses on three key dimensions: engineering, economics, and management. The Plan-Do-Check-Act (PDCA) method was employed to establish performance indicators and guide continuous improvement initiatives. A 5S system was implemented to optimize the organization of high racks, resulting in a 3.7% reduction in downtime. Standardized work protocols were developed to promote one-piece flow, and operator cycle time balancing was applied to a specific component (Part X). These efforts led to a 30.77% improvement in productivity, with the line now producing 17 pieces of Part X per hour, compared to the previous output. The cycle time for producing one finished good part was reduced by 132 seconds, from 950 seconds to 818 seconds, and the welding robot was strategically designated as the bottleneck to further streamline operations.Economically, the reallocation of operators reduced Daily Labor Cost, creating a surplus of 0.64 hours (38 minutes) per operator per shift. This surplus allows operators to support other tasks or production lines, demonstrating the potential for ongoing resource optimization. Additionally, the integration of digitalized standardized work protocols facilitated training and streamlined production processes.The results highlight the transformative impact of lean manufacturing principles, including reduced downtime, improved cycle times, and optimized labor allocation. This study underscores the importance of lean tools in driving operational excellence and achieving measurable improvements in manufacturing efficiency, providing a practical framework for continuous improvement in the automotive industry.

• Periodical: Advances in Science and Technology (Volume 165)
• Pages: 243-262
• DOI: https://doi.org/10.4028/p-8bZQhF
• Online since: June 2025
• Authors: Alkholi Sahab*, Mirzaiee Ebrahim, Daróczi Miklós
• Keywords: 5S System, Continuous Improvement, Cycle Time Diagram, Daily Labor Cost, Key Performance Indicator (KPI), Lean Manufacturing, Plan-Do-Check-Act (PDCA) Method, Standardized Work

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