EVALUATION OF PRODUCTION FLOW OF A NIGERIAN MEDIUM SCALE MANUFACTURING COMPANY USING LEAN MANUFACTURING PRINCIPLES

Abstract

The increasing customers’ demands, in terms of speed of service and reduced cost at higher quality, have generated a new platform on which manufacturing companies compete. This challenge has driven all manufacturing companies to introducing lean manufacturing principles into their production systems. This report focuses on the analysis of the current state value stream mapping of a case study company and then proposes a future state mapping to the company. The refurbishing flow process of Figoglass Nigeria limited, Ibadan, was carefully evaluated. Data were collected at the Gemba (i.e. the shop floor) through interviewing and time study, making use of stop watch. The data collected were carefully analysed. However, the production lead time for the refurbishing flow process was reduced by 61.8% i.e from 401589s to 153600s. About 95% waste was found in the current refurbishing process and the waste identified include waste due to waiting, waste of motion and transportation of chillers, waste of inventory and waste of defect. The future state value stream mapping designed for the company can be achieved by implementing kaizen, 5S principle and kanban pulling