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Lean Manufacturing Practices Assessment Case Study of Automotive Company

Hąbek Patrycja, Lavios Juan J, Grzywa Adam

Production Engineering Archives

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2023

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Vol. 29, Iss. 3

311-318

EN

Lean Manufacturing (LM) practices have gained popularity as a means to achieve high-quality products while reducing costs and delivery times. However, the implementation of LM can be challenging, with a high failure rate. This paper aims to explore the perspectives of employees and managers on LM practices implemented in an automotive company. The research involved primary and secondary data analysis, combining observation, interviews, and a questionnaire survey. The survey assessed knowledge and skills, impact on quality improvement, motivation, supervisor support, control, and engagement in LM development. The results highlight the importance of management commitment and support in achieving successful LM implementation. Moreover, the study emphasises the positive impact of LM practices on employee motivation and the overall quality of processes and products. The PDCA cycle emerged as the most impactful tool, along with other recognised tools like Poka Yoke, Andon, Kaizen, Visual Management, and the 5S method. The findings contribute to understanding the implementation and effects of LM practices, providing insights for companies seeking improvement through Lean Manufacturing methodologies.

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Logistics engineering in logistic processes designing

Michlowicz E., Mindur L.

Logistics and Transport

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2018

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Vol. 38, No. 2

53--62

EN

In the systemic approach, each enterprise, (production, transport, commercial) is a complex system of objects and relations between these objects, as well as between the system and its surrounding. As a result of the multitude of variables and indicators of the company's performance assessment, the methods of formalizing the existing relationships are still being sought. Logistics engineering is the field of knowledge which, through the integration of many processes, enables finding practical solutions. It is a rarely used term in Poland, meanwhile, for example in the USA, logistics engineering, using mathematical methods, learning achievements is a commonly used tool, supporting business operations. The article presents primary tasks and possibilities of logistics engineering.

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Aircraft fault forecasting at maintenance service on the basis of historic data and aircraft parameters

Pogačnik B., Duhovnik J., Tavčar J.

Eksploatacja i Niezawodność

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2017

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Vol. 19, no. 4

624--633

EN

Aircraft maintenance and repair organizations (MROs) have to be competitive and attractive for both existing and new customers. The aircraft ground time at MROs should be as short as possible and cost effective without reducing the quality of the work. Process optimization in MROs requires the continuous improvement of processes and the elimination of non-value-added activities during maintenance checks. There is, on the one hand, an obligation to follow the prescribed procedures and, on the other hand, pressure for time and cost reduction. The aircraft servicing process has been analysed according to a lean methodology. The optimization of logistics processes is recognized as the most promising method for reducing the maintenance service time and costs of spare parts. The probability of aircraft faults is calculated on the basis of historic data from previously completed service projects. Aircraft parameters, such as aircraft type, operator, aircraft age, flight hours, flight cycles, engine type and operation location, are taken into consideration in the fault forecasting. The fault probability is used as an indicator for defining a priority list for the accomplishment of jobs included in the aircraft maintenance service. The proposed methodology was validated and confirmed on four different projects.

PL

Organizacje zajmujące się konserwacją i naprawami statków powietrznych (MRO) muszą dbać o swoją konkurencyjność i atrakcyjność zarówno dla istniejących jak i nowych klientów. Czas trwania obsługi naziemnej w MRO powinien być jak najkrótszy a konserwacja powinna pociągać za sobą jak najmniejsze koszty, bez konieczności obniżania jakości pracy. Optymalizacja procesów przeprowadzanych w MRO wymaga ciągłego doskonalenia oraz eliminacji nieuzasadnionych czynności przeglądowych. Z jednej strony pracownicy MRO muszą przestrzegać określonych procedur, z drugiej zaś strony, ciąży na nich presja redukcji czasu i kosztów obsługi. Proces obsługi statku powietrznego analizowano zgodnie z metodologią szczupłego utrzymania ruchu. Optymalizację procesów logistycznych uznaje się za najbardziej obiecujący sposób redukcji czasu obsługi serwisowej oraz kosztów części zamiennych. Prawdopodobieństwo wystąpienia uszkodzeń statku powietrznego obliczano na podstawie danych historycznych z uprzednio przeprowadzonych prac obsługowych. W prognozowaniu uszkodzeń, uwzględniano takie parametry statku powietrznego, jak typ statku, jego operator, wiek, liczba godzin w powietrzu, liczba cykli lotów, typ silnika oraz miejsce stacjonowania. Prawdopodobieństwo wystąpienia uszkodzeń wykorzystano jako wskaźnik do hierarchizacji zadań obsługi technicznej statku powietrznego. Przydatność proponowanej metodologii zweryfikowano i potwierdzono na przykładzie czterech różnych projektów.

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Research on the Flow of Material in Production Logistics

Michlowicz E., Smolińska K.

Research in Logistics & Production

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2015

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Vol. 5, No. 1

21--31

EN

The primary objective of production logistics, in accordance with the laws of 7R, is the supply of the right product, in the right quantity and condition, in the right place, at the right time, to the right customer, at the right price. Specific objectives may, however, be different: they may include improvement of flow continuity (e.g. Womack, Rother) or increased reliability and volume of deliveries (Nyhuis & Wiendhal). In his work, nyhuis, in order to analyse and formalise ongoing flow dependencies, suggests the application of nine laws of production logistics. The article includes a description of these nine critical laws of production logistics and the proposal of the author’s own algorithms for use in the quest to improve the continuity of flow.

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Logistics Engineering in a Production Company

Michlowicz E., Smolińska K., Zwolińska B.

Research in Logistics & Production

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2015

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Vol. 5, No. 5

503--513

EN

In the systemic approach, a production company is a complex system of objects and the relations between the objects as well as between the system and its surroundings. The large number of variables and company performance assessment indicators results in the constant search for the methods of formalising the mutual dependencies. The discipline which, through the integration of multiple processes, enables the discovery of practical solutions is logistics engineering. In Poland, the term is not very common, while in the USA (for example), logistics engineering – taking advantage of mathematical methods and cutting edge science is a widely used tool supporting the everyday business activities of companies. The article describes primary tasks of logistics engineering in relation to production companies. Furthermore, original algorithms for the improvements of company productivity are presented.

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Algorithms for improve efficiency in logistics production

Michlowicz E.

Logistyka

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2015

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nr 2

584--592, CD1

EN

The areas of production logistics and manufacturing engineering share a field that is currently growing. The primary objective of production logistics, in accordance with the laws of 7W, is the supply of the right product, in the right quantity and condition, in the right place, at the right time, to the right customer, at the right price. Specific objectives may, however, be different: they may include improvement of flow continuity (e.g. Womack, Rother) or increased reliability and volume of deliveries (Nyhuis, Wiendhal). In pursuit of these objectives, one can use different methods and tools. These include integrated ERP systems and the widely understood Lean system (e.g. production, manufacturing) utilising the socalled ‘lean toolbox’. In his work, Nyhuis, in order to analyse and formalise ongoing flow dependencies, suggests the application of nine laws of production logistics. The article includes a description of the proposal of the author’s own algorithms for use in the quest to improve the continuity of flow.

PL

Podstawowy cel logistyki produkcji to, zgodnie z prawami 7W, dostarczenie właściwego produktu, we właściwej ilości i stanie, we właściwe miejsce, we właściwym czasie, właściwemu klientowi, po właściwej cenie. Cele szczegółowe mogą być jednak różne: może to być poprawa ciągłości przepływu (np. Womack, Rother) czy też zwiększenie niezawodności i wielkości dostaw (Nyhuis, Wiendhal). W dążeniu do realizacji tych celów można stosować różne metody i narzędzia. Artykuł zawiera propozycję własnych algorytmów możliwych do stosowania przy dążeniu do poprawy ciągłości przepływów materiałowych w systemach wytwarzania.