IMPLEMENTATION OF LEAN MANUFACTURING PRINCIPLES IN A PRODUCTION FACILITY

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IMPLEMENTATION OF LEAN MANUFACTURING PRINCIPLES IN A PRODUCTION FACILITY

ABSTRACT

The immediate impact of the economic downturn and challenging market condition on manufacturing companies and businesses is an urgent demand to implement the effective resource utilization and processing system that will improve productivity. Effective adaptation to the highly competitive environment entails integrating different thought concepts and inventive ideas into the manufacturing companies processes to reduce manufacturing costs, wastes and improve quality. This paper explores the use of lean concept in COMPANIES to improve productivity by reducing operator motion distances, processing time and cost of energy supply. The project reviewed productivity improvement opportunities in Campus bread factory Nsukka using lean principle. The problems in the existing layout were carefully delineated through direct observation of production processes and detailed work study. The resulting data were analyzed to enable the proposal of pertinent modifications in the process. When compared with the existing methods, the new developed method revealed at least 15.62% reduction opportunity in the distance travelled by the operator and decreased the process time by 13.09%. The results also showed that 35.99% reduction of cost of power generation is achievable. A new layout is proposed based on the research realities.

TABLE OF CONTENTS

TITLE PAGE

CERTIFICATION PAGE

DEDICATION

ACKNOWLEDGEMENT

ABSTRACT

TABLE OF CONTENTS

CHAPTER ONE

INTRODUCTION

BACKGROUND OF THE STUDY
1. STATEMENT OF PROBLEMS
1. OBJECTIVE OF THE STUDY
1. PURPOSE OF THE STUDY
1. RESEARCH QUESTION
1. SIGNIFICANCE OF THE STUDY
1. ADVANTAGES OF THE STUDY
1. LIMITATION OF THE STUDY

CHAPTER TWO

REVIEW OF RELATED LITERATURE

ORIGIN OF THE STUDY
- REVIEW OF LEAN SUPPLY CHAIN MANAGEMENT
- THE SUPPLY CHAIN CYCLE
- THE LEAN SUPPLY CHAIN
- BENEFITS AND LIMITATIONS OF IMPLEMENTING A LEAN SUPPLY CHAIN
- APPLICATION OF WASTE AVOIDANCE TO AN ORGANISATION IN EFFORTS TO INITIATE A LEAN SUPPLY CHAIN
- LEAN PRINCIPLES SUITABLE FOR THE PRODUCTION AND PACKAGING INDUSTRY

CHAPTER THREE

RESEARCH METHODOLOGY
- MATERIALS AND METHODS
- PRODUCTION PROCESSES
- CURRENT LAYOUT
- TIME STUDY
- TAKE TIME CALCULATION
- CYCLE TIME CALCULATION
- SAMPLE USED

CHAPTER FOUR

DATA COLLECTION PRESENTATION AND ANALYSIS

PROBLEMS IDENTIFIED IN THE CURRENT LAYOUT
- WASTE IN TRANSPORTATION BY MANUAL OPERATION
- ELECTRICAL ENERGY SOURCES IN THE CURRENT LAYOUT
- PROPOSED LAYOUT
- ALTERNATIVE ENERGY SOURCE
- SOLAR ENERGY SYSTEMS

CHAPTER FIVE

5.1 CONCLUSION

5.2 DISCUSSION

5.3 REFERENCES

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