Process Improvement Model based on Lean Manufacturing and Kaizen to Increase Machine Availability at a Plastics Company

N. Caso-Murillo; R. Leon Mejia; J. Quiroz-Flores

doi:10.1063/5.0119321

Process Improvement Model based on Lean Manufacturing and Kaizen to Increase Machine Availability at a Plastics Company

N. Caso-Murillo
, R. Leon Mejia
, J. Quiroz-Flores

Research output: Chapter in Book/Report › Conference contribution › peer-review

5 Scopus citations

Abstract

The case study is a company that produces and sells plastic containers. Through a production time assessment, the low availability of injection machines was identified as the mam problem. The availability rate for these machines was set at 80.19%, which represented a relevant issue since the worldwide standard is 90%. These low availability rates are mainly due to machine breakdowns, representing 9.87% in lost revenue for the company. To improve machine availability, this study proposed an improvement model combining Lean Manufacturing tools with Kaizen, which refers to continuous process improvement. The model is also integrated with Ergonomics concepts aimed at improving working conditions for operators. Hence, if improvements are achieved regarding human capital, machine availability will also improve. Within this context, the proposed model was piloted at the company, increasing machine availability by 6.8%, reducing lost revenue by 3.9%, and increasing company profits by 13.12%.

Original language	American English
Title of host publication	11th Annual International Conference, AIC 2021
Subtitle of host publication	On Sciences and Engineering
Editors	Iskandar Abdul Samad, Akhyar
Publisher	American Institute of Physics Inc.
ISBN (Electronic)	9780735443112
DOIs	https://doi.org/10.1063/5.0119321
State	Indexed - 30 Jan 2023
Externally published	Yes
Event	11th Annual International Conference: On Sciences and Engineering, AIC 2021 - Banda Aceh, Indonesia Duration: 29 Sep 2021 → 30 Sep 2021

Publication series

Name	AIP Conference Proceedings
Volume	2613
ISSN (Print)	0094-243X
ISSN (Electronic)	1551-7616

Conference

Conference	11th Annual International Conference: On Sciences and Engineering, AIC 2021
Country/Territory	Indonesia
City	Banda Aceh
Period	29/09/21 → 30/09/21

Bibliographical note

Publisher Copyright:
© 2023 American Institute of Physics Inc.. All rights reserved.

Access to Document

10.1063/5.0119321

Cite this

Caso-Murillo, N., Leon Mejia, R., & Quiroz-Flores, J. (2023). Process Improvement Model based on Lean Manufacturing and Kaizen to Increase Machine Availability at a Plastics Company. In I. A. Samad, & Akhyar (Eds.), 11th Annual International Conference, AIC 2021: On Sciences and Engineering Article 020016 (AIP Conference Proceedings; Vol. 2613). American Institute of Physics Inc.. https://doi.org/10.1063/5.0119321

@inproceedings{1d2d43427e464893bbc24b8be9e40dce,

title = "Process Improvement Model based on Lean Manufacturing and Kaizen to Increase Machine Availability at a Plastics Company",

abstract = "The case study is a company that produces and sells plastic containers. Through a production time assessment, the low availability of injection machines was identified as the mam problem. The availability rate for these machines was set at 80.19\%, which represented a relevant issue since the worldwide standard is 90\%. These low availability rates are mainly due to machine breakdowns, representing 9.87\% in lost revenue for the company. To improve machine availability, this study proposed an improvement model combining Lean Manufacturing tools with Kaizen, which refers to continuous process improvement. The model is also integrated with Ergonomics concepts aimed at improving working conditions for operators. Hence, if improvements are achieved regarding human capital, machine availability will also improve. Within this context, the proposed model was piloted at the company, increasing machine availability by 6.8\%, reducing lost revenue by 3.9\%, and increasing company profits by 13.12\%.",

author = "N. Caso-Murillo and \{Leon Mejia\}, R. and J. Quiroz-Flores",

note = "Publisher Copyright: {\textcopyright} 2023 American Institute of Physics Inc.. All rights reserved.; 11th Annual International Conference: On Sciences and Engineering, AIC 2021 ; Conference date: 29-09-2021 Through 30-09-2021",

year = "2023",

month = jan,

day = "30",

doi = "10.1063/5.0119321",

language = "American English",

series = "AIP Conference Proceedings",

publisher = "American Institute of Physics Inc.",

editor = "Samad, \{Iskandar Abdul\} and Akhyar",

booktitle = "11th Annual International Conference, AIC 2021",

}

Caso-Murillo, N, Leon Mejia, R & Quiroz-Flores, J 2023, Process Improvement Model based on Lean Manufacturing and Kaizen to Increase Machine Availability at a Plastics Company. in IA Samad & Akhyar (eds), 11th Annual International Conference, AIC 2021: On Sciences and Engineering., 020016, AIP Conference Proceedings, vol. 2613, American Institute of Physics Inc., 11th Annual International Conference: On Sciences and Engineering, AIC 2021, Banda Aceh, Indonesia, 29/09/21. https://doi.org/10.1063/5.0119321

Process Improvement Model based on Lean Manufacturing and Kaizen to Increase Machine Availability at a Plastics Company. / Caso-Murillo, N.; Leon Mejia, R.; Quiroz-Flores, J.
11th Annual International Conference, AIC 2021: On Sciences and Engineering. ed. / Iskandar Abdul Samad; Akhyar. American Institute of Physics Inc., 2023. 020016 (AIP Conference Proceedings; Vol. 2613).

Research output: Chapter in Book/Report › Conference contribution › peer-review

TY - GEN

T1 - Process Improvement Model based on Lean Manufacturing and Kaizen to Increase Machine Availability at a Plastics Company

AU - Caso-Murillo, N.

AU - Leon Mejia, R.

AU - Quiroz-Flores, J.

PY - 2023/1/30

Y1 - 2023/1/30

N2 - The case study is a company that produces and sells plastic containers. Through a production time assessment, the low availability of injection machines was identified as the mam problem. The availability rate for these machines was set at 80.19%, which represented a relevant issue since the worldwide standard is 90%. These low availability rates are mainly due to machine breakdowns, representing 9.87% in lost revenue for the company. To improve machine availability, this study proposed an improvement model combining Lean Manufacturing tools with Kaizen, which refers to continuous process improvement. The model is also integrated with Ergonomics concepts aimed at improving working conditions for operators. Hence, if improvements are achieved regarding human capital, machine availability will also improve. Within this context, the proposed model was piloted at the company, increasing machine availability by 6.8%, reducing lost revenue by 3.9%, and increasing company profits by 13.12%.

AB - The case study is a company that produces and sells plastic containers. Through a production time assessment, the low availability of injection machines was identified as the mam problem. The availability rate for these machines was set at 80.19%, which represented a relevant issue since the worldwide standard is 90%. These low availability rates are mainly due to machine breakdowns, representing 9.87% in lost revenue for the company. To improve machine availability, this study proposed an improvement model combining Lean Manufacturing tools with Kaizen, which refers to continuous process improvement. The model is also integrated with Ergonomics concepts aimed at improving working conditions for operators. Hence, if improvements are achieved regarding human capital, machine availability will also improve. Within this context, the proposed model was piloted at the company, increasing machine availability by 6.8%, reducing lost revenue by 3.9%, and increasing company profits by 13.12%.

UR - https://www.scopus.com/pages/publications/85147990605

U2 - 10.1063/5.0119321

DO - 10.1063/5.0119321

M3 - Conference contribution

AN - SCOPUS:85147990605

T3 - AIP Conference Proceedings

BT - 11th Annual International Conference, AIC 2021

A2 - Samad, Iskandar Abdul

A2 - Akhyar, null

PB - American Institute of Physics Inc.

T2 - 11th Annual International Conference: On Sciences and Engineering, AIC 2021

Y2 - 29 September 2021 through 30 September 2021

ER -

Caso-Murillo N, Leon Mejia R, Quiroz-Flores J. Process Improvement Model based on Lean Manufacturing and Kaizen to Increase Machine Availability at a Plastics Company. In Samad IA, Akhyar, editors, 11th Annual International Conference, AIC 2021: On Sciences and Engineering. American Institute of Physics Inc. 2023. 020016. (AIP Conference Proceedings). doi: 10.1063/5.0119321

Process Improvement Model based on Lean Manufacturing and Kaizen to Increase Machine Availability at a Plastics Company

Abstract

Publication series

Conference

Bibliographical note

Access to Document

Fingerprint

Cite this