Presented in Partial Fulfilment of The Requirement for The Degree of Master of Science in Mechanical Engineering (Industrial Engineering Stream)
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Date
2018-10
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Addis Ababa University
Abstract
This main concern of this study is to improve the productivity of the factory by LEAN
approach. The purpose of lean in production is to increase productivity, improve product
quality, reduce lead time and eliminate manufacturing waste. The study has been conducted on
C&H Garment factory that produces different men’s and women’s garment products, located
in Bole Lemmi industry park Addis Ababa.
On an earlier stage, a literature review on lean was conducted, from the creation of the concept
of LEAN to its main tools and techniques. Valuable data has been collected from the case study
(C&H Garment Company) by observation, and interview from management body. The
collected data has been analyzed according to the relevant time. For this purpose MS-excel,
statistical tools, MS-Visio have been applied; in addition to these, industrial or lean tools were
considered.
The research approach considers the existing factory manufacturing culture and the lost events
with respect to lean tools and techniques, to determine the lean tool gap the main waste of lean
are identified with case company. Besides waste of lean absenteeism is one crucial event on
factory productivity, included on study.
Finally, lean productivity improvement methods were propose. But in practical validation of
lean tool 5why methods have been exercised to improve rework and defects , based on the
average defect rate ,production rate, cycle time, production costs were improve by
40.91%,50.85%,13%,40.91%, respectively. Cellular manufacturing and other approaches have
not been implemented, although the company has been left prepared for an implementation in
the future.
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Keywords
lean, productivity improvement, VSM, 5why method