Integrating Big Island Layout with Pull System for Production Optimization
Lean manufacturing is a production philosophy made
popular by Toyota Motor Corporation (TMC). It is globally known as
the Toyota Production System (TPS) and has the ultimate aim of
reducing cost by thoroughly eliminating wastes or muda. TPS
embraces the Just-in-time (JIT) manufacturing; achieving cost
reduction through lead time reduction. JIT manufacturing can be
achieved by implementing Pull system in the production.
Furthermore, TPS aims to improve productivity and creating
continuous flow in the production by arranging the machines and
processes in cellular configurations. This is called as Cellular
Manufacturing Systems (CMS). This paper studies on integrating the
CMS with the Pull system to establish a Big Island-Pull system
production for High Mix Low Volume (HMLV) products in an
automotive component industry. The paper will use the build-in JIT
system steps adapted from TMC to create the Pull system production
and also create a shojinka line which, according to takt time, has the
flexibility to adapt to demand changes simply by adding and taking
out manpower. This will lead to optimization in production.
[1] Allen, J., Robinson, C., and Stewart, D. (2001), Lean Manufacturing: A
plant floor guide, Dearborn, Michigan: Society of Manufacturing
Engineers.
[2] Liker, J.K. (1998). Becoming lean, Portland, OR: Productivity Press.
[3] Shahrukh A. Irani (1999), Handbook of Cellular Manufacturing
Systems: Wiley-Interscience.
[4] Tapping, D., Luyster, T., & Shuker, T. (2002). Value stream
management: Eight steps to planning, mapping, and sustaining lean
improvements. New York, NY: Productivity Press.
[5] Toyota Institute, Toyota Motor Corporation (2001) The Toyota Way
2001.
[6] Womack, J.P. and Jones, D.T. (2003), Lean Thinking: Banish waste and
create wealth in your organization. New York: Free Press.
[7] Serope Kalpakjian and Steven Schmid, Manufacturing engineering and
technology, 5th edition, Prentice Hall, 2006.
[1] Allen, J., Robinson, C., and Stewart, D. (2001), Lean Manufacturing: A
plant floor guide, Dearborn, Michigan: Society of Manufacturing
Engineers.
[2] Liker, J.K. (1998). Becoming lean, Portland, OR: Productivity Press.
[3] Shahrukh A. Irani (1999), Handbook of Cellular Manufacturing
Systems: Wiley-Interscience.
[4] Tapping, D., Luyster, T., & Shuker, T. (2002). Value stream
management: Eight steps to planning, mapping, and sustaining lean
improvements. New York, NY: Productivity Press.
[5] Toyota Institute, Toyota Motor Corporation (2001) The Toyota Way
2001.
[6] Womack, J.P. and Jones, D.T. (2003), Lean Thinking: Banish waste and
create wealth in your organization. New York: Free Press.
[7] Serope Kalpakjian and Steven Schmid, Manufacturing engineering and
technology, 5th edition, Prentice Hall, 2006.
@article{"International Journal of Mechanical, Industrial and Aerospace Sciences:63137", author = "M. H. M. Rusli and A. Jaffar and M. T. Ali and S. Muhamud @ Kayat", title = "Integrating Big Island Layout with Pull System for Production Optimization", abstract = "Lean manufacturing is a production philosophy made
popular by Toyota Motor Corporation (TMC). It is globally known as
the Toyota Production System (TPS) and has the ultimate aim of
reducing cost by thoroughly eliminating wastes or muda. TPS
embraces the Just-in-time (JIT) manufacturing; achieving cost
reduction through lead time reduction. JIT manufacturing can be
achieved by implementing Pull system in the production.
Furthermore, TPS aims to improve productivity and creating
continuous flow in the production by arranging the machines and
processes in cellular configurations. This is called as Cellular
Manufacturing Systems (CMS). This paper studies on integrating the
CMS with the Pull system to establish a Big Island-Pull system
production for High Mix Low Volume (HMLV) products in an
automotive component industry. The paper will use the build-in JIT
system steps adapted from TMC to create the Pull system production
and also create a shojinka line which, according to takt time, has the
flexibility to adapt to demand changes simply by adding and taking
out manpower. This will lead to optimization in production.", keywords = "Big Island layout, Lean manufacturing, Material and
Information Flow Chart, Pull system production, TPS.", volume = "6", number = "12", pages = "2839-5", }