Application of lean production to reducing operational waste in a tile manufacturing process

Abstract

Roofing tile manufacturing is a mass production process with high operational and inventory wastes and costs. Due to huge operational costs, excessive inventory and wastes, and quality problems, roofing tile manufacturers are trying to implement lean manufacturing practice in their operations in order to remain competitive in an increasingly competitive global market. The aim of this research is to evaluate the possibility of reducing the operational and inventory costs of the tile manufacturing process through waste minimization. This paper analyses the current waste situation in a tile manufacturing process and develops current and future value stream mapping for such a process with a view to implementing lean principles in manufacturing. The focus of the approach is on cost reduction by eliminating non-value-added activities.

Keywords:

• lean production
• waste reduction
• production cost

Acknowledgements

The work presented in this paper has set a basis for future work that can be used to develop lean production systems and possibly step up to higher techniques such as Six Sigma.