Assessment, Evaluation and Enhancement of Operational Performance of Metal Fabrication Factory for Cargo Body, Van Body and Trailer Fabrication Through Lean Practice (A Case of KAKI PLC)
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Date
2024-06
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Addis Ababa University
Abstract
This study aims at investigating on assessment, evaluation and enhancement of the operational performance of metal fabrication factory for cargo body, van body and trailer fabrication by using lean practice at case company of Kaki PLC which is located at Addis Ababa around Sebeta (alemgena). The factory has a huge capacity but has a low operational performance and a large waste. The assessment and evaluation are performed on selected three major product types of the case company based on their demand volume and product nature. Using value stream mapping assessment of the current fabrication process of each product and identify the major waste of the company which are waiting time, defect, unnecessary movement and inventory and large setup time. During the investigation the data are collected by direct observation and using stop watch and the company document is also referred. Then by using cause and effect diagram, further analysis is conducted to identify the root causes for the bottlenecks which is found the poor layout of the factory.
The research work is proceeded to develop the solution standing from the assessment and evaluation result. The developed solution is designing new product lay out for three product mix namely NPR van, FSR cargo and trailer by using systematic layout planning, future value stream mapping as a model. In addition to product layout applying an oven in painting process and using simple press machine is the axle preparation in trailer fabrication process. Finally, the solution bring a significant operational performance improvement of the fabrication process of each product mix. The process efficiency of NPR van is improved by 25.4%, the process efficiency of FSR cargo improved by 31.9% and the process efficiency of trailer if improved by 32.42%.
To conclude this research work is conducted the assessment and evaluation process by using value stream mapping and cause and effect diagram and also using questioner. Then design new product layout for the factory using systematic layout planning. That will bring a valuable operational performance improvement.
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performance, value stream mapping, key performance indicator, lean production, layout