Posted by: Zrak-DKS D.o.o.

Status: Solved

Task Description:

Kaizen is a LEAN approach to continuous process improvement based on the systematic identification of problems and opportunities for improvement, as well as the gradual reduction of time, costs, waste, and other losses in the process. Within the rationalization of a manufacturing process, Kaizen can be applied by focusing improvement activities on operations that have the greatest impact on the total manufacturing time of the product.

For the production of the worm screw L195, an annual quantity of 1,000 pieces is planned, with a production batch size of 100 pieces. Due to the long total manufacturing time and, consequently, high production costs, it is necessary to analyze opportunities for rationalizing the manufacturing process and reducing the duration of individual operations.

The following activities should be carried out:

‒ Calculate the annual workload of individual operations.

‒ Perform an ABC/Pareto analysis of the operations according to their contribution to the total manufacturing time of the worm screw.

‒ Construct a cumulative curve and identify the operations belonging to areas A, B, and C.

‒ Analyze the operations in Area A and identify possible causes of their long duration.

‒ Propose Kaizen improvements for the operations with the greatest impact on the total manufacturing time, with the aim of reducing operation times and overall production costs.

‒ For each proposed improvement, state the expected effect on manufacturing time and explain how it can be implemented.

‒ Calculate the total manufacturing time before and after the proposed Kaizen improvements and determine the percentage reduction in manufacturing time achieved.

‒ Based on the results of the analysis, provide a proposal for continuous monitoring and further improvement of the manufacturing process.