Applying of Lean Management to Increase Organization Efficiency: "ABC” Plant Case Study

Abstract

 The lean management tools problem-solving methodology is one of several techniques used to eliminate organization waste. This paper demonstrates the empirical application of lean tools methodology to reduce production waste though investigation of root causes of non-added values activities and provide a solution to reduce/eliminate these activities. Also, it will give a basic idea about the historical developments that led to Lean Methodology including evolution of Lean, a basic idea about Lean and its concept, what it is about and its methodology. It will also brief about Lean Manufacturing's integration and how it has helped in process improvement, how Lean enhanced and the initiators of Lean (successful case studies). The researcher explains the effective use of resources, usually expressed as the ratio of output to input, focusing on frequency of dismissal of spare parts. In addition, the organization structure, Engineering team, Detailed processes of dismissal of spare parts that are used during downtime hours, MTTR, MTBF, spare parts location management, True efficiency, Net efficiency the organization development was, also explained. Zero downtime and zero losses from decreasing downtime duration in operation by eliminating non added values in the processes using lean management to increase organization production efficiency using specific lean tools. In the world of competition, Lean Manufacturing is considered as a fast-growing and efficient approach. Lean Manufacturing is applied to remove manufacturing wastes continuously to increase the productivity and efficiency. The aim of the lean manufacturing is not only high quality but also low cost for the satisfaction of customers' demands. The benefit of this technique is not only the removal of wastes but also identification of the reasons causing them through specific guidelines and principles. Customers' requirements: Internal customer needs delivery of spare parts on time and seeks for implementation of maintenance management system documents and facilitates spare parts dismissal documents. In this research, I have decided to choose the multi-method to combine quantitative and qualitative data collection and analysis in one study. Individually, these approaches can answer different questions, so combining them can provide you with more in-depth findings and qualitative data can show how and why you got these results. Exploratory research design is chosen to gain background information and to define the terms of the research problem. This is used to clarify research problems, hypotheses and to establish research priorities.