Case studies in industry and services
Robert S Keyser; Parisa Pooyan
Abstract
In a lean production environment, reduced setup times can lead to many benefits, including reduced lead times. Previous research has primarily relied on the SMED methodology and mathematical modeling to reduce setup times at machine centers – and both are very useful techniques. We use the Soft ...
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In a lean production environment, reduced setup times can lead to many benefits, including reduced lead times. Previous research has primarily relied on the SMED methodology and mathematical modeling to reduce setup times at machine centers – and both are very useful techniques. We use the Soft Systems Methodology, combined with the Seven Tools of Quality, to provide a structured, illustrative means for diagnosing production and quality issues. A baseline average setup time was established by which future setup times would be compared. The intervention included brainstorming sessions between management and the converting center work crew that disclosed many reasons for increased setup times, some of which were under management’s control. Our findings resulted in a 24% reduction in average setup times and a 62% reduction in the moving range at a bottleneck machine center in the corrugated box industry.
Case studies in industry and services
Robert S Keyser; Parisa Pooyan
Abstract
Root cause analysis techniques are often applied to problems in the workplace; however, they may also prove very useful to home projects. This research explores the application of two root cause analysis techniques in home projects: (1) 5 Whys to determine the root cause of a home air conditioning unit ...
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Root cause analysis techniques are often applied to problems in the workplace; however, they may also prove very useful to home projects. This research explores the application of two root cause analysis techniques in home projects: (1) 5 Whys to determine the root cause of a home air conditioning unit that runs continuously but does not cool, and (2) an innovative Lean PFMEA to repair a John Deere riding mower that starts, then stops. Employing the 5 Whys technique led to the discovery of incorrect color-coded wiring from the original air conditioning unit to the thermostat. Lean PFMEA enabled a correct diagnosis and resolution of the mower start/stop issue via a Kaizen event, grass clippings in the fuel line, which was remedied by cleaning the fuel tank and replacing the fuel lines, fuel filter, and carburetor. These techniques provide Lean methodological approaches to problem-solving, which often leads to reduced homeowner aggravation, repair time, and repair expense.