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1
Content available The impact of selected lean manufacturing tools on the level of delays in the production process. A case study
Pawlak Szymon
Management Systems in Production Engineering
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2024
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nr 1 (32)
103--107
EN
Organizing manufacturing work in a way that minimizes delays in individual production operations is a key factor in a highly competitive market. One of the key factors to prevent delays is their correct identification and proper definition of methods to reduce their impact on selected parameters of the production process. The study pre-sents the impact of Lean Manufacturing tools (5S, standardization and Total Productive Maintenance) on delays in the manufacturing process. A statistical analysis of the level of delays was performed, which was aimed at showing the essence of using Lean Manufacturing tools to improve the efficiency of the production process. In the example analyzed, the implementation of selected LM tools allowed for a reduction of delays related to fail-ures by approximately 18 hours.
2
Content available The use of the DPMO indicator to verify the fulfilment of hygienic requirements in the food industry - a case study
Pawlak Szymon, Miranowicz Andrzej Krzysztof, Nowacki Krzysztof
Agricultural Engineering
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2024
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Vol. 28, No. 1
23--35
EN
The quality of the manufactured product plays a special role in the food industry. Food producers, in addition to meeting consumer requirements, are obliged to comply with legally sanctioned, rigorous requirements of hygiene and cleanliness at work, as well as the way it is performed. In order to maintain the legally required hygiene rules in production plants specializing in the production of food products, manufacturers implement numerous management systems aimed at maintaining legally imposed guidelines in the field of quality management and occupational health. The article describes the use of the DPMO indicator, which allows for a thorough analysis of process parameters affecting the final quality of the manufactured product. For the analyzed process, the maximum DPMO value for one of the areas is 636364. In nine cases, which constitutes 12.5% of the total, DPMO is 0. The purpose of this article is to identify non-compliances in the field of occupational hygiene in the production plant analyzed using the DPMO indicator and then to introduce improvements. The developed recommendations concern marking, standardization and responsibility for individual processes as well as additional cleanliness inspections.
PL
Jakość wyprodukowanych towarów spełnia bardzo istotną rolę w przemyśle spożywczym. Producenci żywności, oprócz spełnienia wymogów konsumenckich, są zobowiązani do przestrzegania prawnie usankcjonowanych, rygorystycznych wymagań dotyczących higieny i czystości w pracy oraz sposobu w jakim jest wykonywana. W celu zachowania wymaganych prawem zasad higieny w fabrykach produkcyjnych specjalizujących się w produkcji towarów spożywczych, producenci wdrażają liczne systemy zarządzania mające na celu przestrzeganie wytycznych w obszarze jakości zarządzania i bezpieczeństwa i higieny pracy. Niniejszy artykuł opisuje zastosowanie wskaźnika DPMO, który pozwala na dokładną analizę parametrów procesu, jakie wpływają na ostateczną jakość wyprodukowanych towarów. Dla analizowanego procesu, maksymalna wartość DPMO dla jednego z obszarów wynosi 636364. W dziewięciu przypadkach, które stanowią 12,5 % całości, DPMO wynosi 0. Celem niniejszego artykułu jest identyfikacja niezgodności w obszarze higieny i bezpieczeństwa pracy w fabryce przeanalizowanej za pomocą wskaźnika DPMO a następnie wprowadzenie ulepszeń. Opracowane zalecenia dotyczą oznaczania, standaryzacji oraz odpowiedzialności za indywidulane procesy oraz dodatkowych inspekcji czystości.
3
Content available Analysis of the impact of selected Lean Manufacturing tools on the parameters of the production process - case study
Pawlak Szymon
Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska
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2023
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z. 175
379--392
EN
Purpose: The aim of the research was to present the impact of the use of selected Lean Manufacturing tools (5S and Poka Yoke) on the efficiency of the production process and the number of non-conforming products generated during the manufacturing process. The research was carried out on the basis of data from a production plant in the automotive industry. Design/methodology/approach: The article presents a statistical analysis of the impact of the implementation of Lean Manufacturing tools on the production process - a case study. Findings: The obtained results allowed to present the scale of changes coming in the manufacturing process, confirming at the same time the positive effect of the implementation of Lean Manufacturing tools on the efficiency of the manufacturing process and the quality of manufactured products. As a result of the implementation of the 5S and Poka Yoke tools, an increase in efficiency was found in all production operations. Social implications: The analysis carried out can increase awareness of the importance of the impact of Lean Manufacturing on the production process. Originality/value: In the article, an original statistical analysis was carried out, indicating an increase in the efficiency of the production process due to the implementation of selected Lean Manufacturing tools.
4
Content available Analysis of the impact of the 5S tool and Standardization on the duration of the production process - case study
Pawlak Szymon, Nowacki Krzysztof, Kania Harald
Production Engineering Archives
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2023
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Vol. 29, Iss. 4
421-427
EN
The high level of competition in the manufacturing industry requires the creation of working conditions that allow for the efficient implementation of production processes. One of the solutions enabling the adaptation of production stations to improve the work performed by employees is the implementation of a management system based on the Lean Manufacturing (LM) philosophy. The purpose of this article was to determine the potential impact of the implemented LM tools, in the form of 5S and standardization, on the efficiency of the production process in specific production conditions. The methodology of the conducted research included: obtaining data before and after the implementation of LM tools (in total 12 months). The data was used to determine the effectiveness of individual operations, and then to conduct a comparative analysis using statistical tests. It was found, among others, that the implementation of LM tools resulted in an increase in the efficiency of the manufacturing process by about 11 percentage points. The obtained results confirm the thesis that a manufacturing company, in order to maintain its position on a competitive market, can improve the efficiency of processes by using tools such as LM. The selection of tools must be adequate to the implemented processes, so that they bring measurable increase in efficiency.
5
Content available The impact of Industry 4.0 on the employment structure in production plants
Pawlak Szymon
Zeszyty Naukowe. Organizacja i Zarządzanie / Politechnika Śląska
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2022
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z. 160
515--525
EN
Purpose: The aim of the study is to present the changes taking place in the employment structures of production plants, occurring as a result of the implementation of modern production management and control systems as well as the automation of production processes in line with the assumptions of Industry 4.0. Design/methodology/approach: The study uses methods of analyzing literature sources and quantitative research with the use of interviews among production plants implementing new technologies in line with the assumptions of Industry 4.0. Findings: As a result of the analysis, the results were obtained indicating the direction of changes taking place in the employment structures of production plants implementing automation of production processes in line with the assumptions of Industry 4.0. Social implications: The conducted analysis may increase social awareness of the need to adapt the skills and competences of employees to the needs of the market in the Industry 4.0. Originality/value: The article presents an alanlize indicating the direction of changes taking place in the employment structure in production plants implementing the assumptions of Industry 4.0, which were compared with the assumptions of the literature.
6
Content available Inconsistencies in the Production Process Resulting From the Employment Structure
Nowacki Krzysztof, Pawlak Szymon
New Trends in Production Engineering
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2019
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Vol. 2, Iss. 2
205-213
EN
Underestimating the duration of the production process is one of the basic factors determining the occurrence of delays in the duration of individual operations included in the production process. Occurrence of underestimation of production time brings many negative effects, which include, among others: underestimation of the company's production capacity, accumulation of intermediate stocks, impeded planning of the production process (scheduling of the production process) and increase of production costs. The problem of erroneous estimation of the duration of the production process is most often found in production plants specializing in serial or mass production, implemented in a parallel or series-parallel system. The basic causes that underestimate the duration of the production process include errors in production scheduling, incorrect determination of durations of individual operations carried out as part of the analyzed production process, complexity of production operations and employment structure. The occurrence of delays in the production process can also be affected by accident events that generate underestimation and costs for the enterprise (including social and economic costs). In many cases, many algorithms are used to reduce underestimation and optimization and scheduling of the entire production process. The publication presents an analysis of the production process in which the duration of the production process is underestimated, taking into account the employment structure in the manufacturing company. The analyzes allow to determine the level of underestimation of operations of the production process depending on the form of employment (steel workers – employed under a contract of employment in the production plant, and temporary workers employed by temporary work agencies), identification of the reasons for the underestimation of individual production positions and the length of their time occurrence.
7
Wymagania systemu Zakładowej Kontroli Produkcji w aspekcie jakości produktów stalowych
Pawlak Szymon, Nowacki Krzysztof
Hutnik, Wiadomości Hutnicze
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2019
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Vol. 86, nr 5
169--172
PL
Celem artykułu jest określenie wpływu funkcjonowania systemu Zakładowej Kontroli Produkcji (ZKP) w przedsiębiorstwie branży hutniczej specjalizującego się w produkcji prętów stalowych żebrowanych do zbrojenia betonu na jakość wyrobu na każdym etapie procesu produkcyjnego. Poprawa jakości wyrobu ma być skutkiem nieprzerwanej kontroli procesu przeprowadzonej zgodnie z dokumentacją kontrolną, sporządzoną przez producenta (księga jakości, dokumentacja ZKP, instrukcje, procedury). W artykule przedstawiono sposób wdrożenia zasad funkcjonowania systemu ZKP wraz z hipotetyczną analizą wpływu oddziaływania systemu ZKP na jakość produktu i eliminacje potencjalnych niezgodności na każdym etapie procesu produkcyjnego.
EN
The purpose of the article is to determine the impact of the operation of the factory production control system (FPC) in an enterprise in the steel industry specializing in the production of steel bars ribbed to reinforce concrete for the quality of the product at every stage of the production process. Improvement of the product quality is to result from the uninterrupted process control carried out in accordance with the control documentation prepared by the manufacturer (quality book, FPC documentation, instructions, procedures). The article presents the method of implementing the rules of the FPC system operation together with a hypothetical analysis of the impact of the FPC system's impact on product quality and the elimination of potential non-conformities at every stage of the production process.
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