Abstract: The paper is aimed at developing a model to measure the impact of Lean manufacturing deployment on organizational performance. The model will help industry practitioners to assess the impact of implementing Lean constructs on organizational performance. It will also harmonize the measurement models of Lean performance with the house of Lean that seems to have become the industry standard. The sheer number of measurement models for impact assessment of Lean implementation makes it difficult for new adopters to select an appropriate assessment model or deployment methodology. A literature review is conducted to classify the Lean performance model. Pareto analysis is used to select the Lean constructs for the development of the model. The model is further formalized through the use of Structural Equation Modeling (SEM) in defining the underlying latent structure of a Lean system. An impact assessment measurement model developed can be used to measure Lean performance and can be adopted by different industries.
Abstract: Mining industry is known for its appetite to spend sizeable capital on mine equipment. However, in the current scenario, the mining industry is challenged by daunting factors of non-uniform geological conditions, uneven ore grade, uncontrollable and volatile mineral commodity prices and the ever increasing quest to optimize the capital and operational costs. Thus, the role of equipment reliability and maintenance planning inherits a significant role in augmenting the equipment availability for the operation and in turn boosting the mine productivity. This paper presents the Risk Based Maintenance (RBM) planning conducted on mine loading equipment namely Load Haul Dumpers (LHDs) at Vedanta Resources Ltd subsidiary Hindustan Zinc Limited operated Sindesar Khurd Mines, an underground zinc and lead mine situated in Dariba, Rajasthan, India. The mining equipment at the location is maintained by the Original Equipment Manufacturers (OEMs) namely Sandvik and Atlas Copco, who carry out the maintenance and inspection operations for the equipment. Based on the downtime data extracted for the equipment fleet over the period of 6 months spanning from 1st January 2017 until 30th June 2017, it was revealed that significant contribution of three downtime issues related to namely Engine, Hydraulics, and Transmission to be common among all the loading equipment fleet and substantiated by Pareto Analysis. Further scrutiny through Bubble Matrix Analysis of the given factors revealed the major influence of selective factors namely Overheating, No Load Taken (NTL) issues, Gear Changing issues and Hose Puncture and leakage issues. Utilizing the equipment wise analysis of all the downtime factors obtained, spares consumed, and the alarm logs extracted from the machines, technical design changes in the equipment and pre shift critical alarms checklist were proposed for the equipment maintenance. The given analysis is beneficial to allow OEMs or mine management to focus on the critical issues hampering the reliability of mine equipment and design necessary maintenance strategies to mitigate them.
Abstract: The Failure Modes and Effect Analysis (FMEA) is an efficient evaluation technique to identify potential failures in products, processes, and services. FMEA is designed to identify and prioritize failure modes. It proves to be a useful method for identifying and correcting possible failures at its earliest possible level so that one can avoid consequences of poor performance. In this paper, FMEA tool is used in detection of failures of various components of heat exchanger cycle and to identify critical failures of the components which may hamper the system’s performance. Further, a detailed Pareto analysis is done to find out the most critical components of the cycle, the causes of its failures, and possible recommended actions. This paper can be used as a checklist which will help in maintainability of the system.
Abstract: Milk is considered as an essential and complete food.
The present study was conducted at Milk Plant Mohali especially in
reference to the procurement section where the cash inflow was
maximum, with the objective to achieve higher productivity and
reduce wastage of milk. In milk plant it was observed that during the
month of Jan-2014 to March-2014 the average procurement of milk
was Rs. 4, 19, 361 liter per month and cost of procurement of milk is
Rs 35/- per liter. The total cost of procurement thereby equal to Rs.
1crore 46 lakh per month, but there was mismatch in procurementproduction
of milk, which leads to an average loss of Rs. 12, 94, 405
per month. To solve the procurement-production problem Quality
Control Tools like brainstorming, Flow Chart, Cause effect diagram
and Pareto analysis are applied wherever applicable. With the
successful implementation of Quality Control tools an average saving
of Rs. 4, 59, 445 per month is done.
Abstract: Lead time is a critical measure of a supply chain's
performance. It impacts both the customer satisfactions as well as the
total cost of inventory. This paper presents the result of a study on the
analysis of the customer order lead-time for a multinational company.
In the study, the lead time was divided into three stages respectively:
order entry, order fulfillment, and order delivery. A sample of size 2,425 order lines was extracted from the
company's records to use for this study. The sample data entails
information regarding customer orders from the time of order entry
until order delivery. Data regarding the lead time of each stage for
different orders were also provided. Summary statistics on lead time
data reveals that about 30% of the orders were delivered later than the
scheduled due date. The result of the multiple linear regression
analysis technique revealed that component type, logistics parameter,
order size and the customer type have significant impacts on lead
time. Data analysis on the stages of lead time indicates that stage 2
consumed over 50% of the lead time. Pareto analysis was made to
study the reasons for the customer order delay in each stage.
Recommendation was given to resolve the problem.