Lean Manufacturing Analysis using Design of Experiments and Computer Simulation Dr. Baskaran R.*, Dr. Manzoor A. K. Sheik** *Associate Professor, Department of Industrial Engineering, Anna University, Chennai, India **Assistant Professor, Department of Management Studies, Anna University, Chennai, India Online published on 3 May, 2016. Abstract Companies are implementing lean practices to keep pace with the competition and achieve better results. The objective of this project is to identify the factors in an auto electrical industry that significantly affect the throughput time. Making changes in the production process by trial and error method involves high cost and consumes more time. By this method, we can arrive at the best solutions quickly and see the impacts before implementation at minimal cost. In this project, Value Stream Mapping, Computer Simulation and Design of Experiments are used. Value Stream Mapping is used to create a picture of information & items flow (from raw materials to the customer's end product) through the value stream. From the current value stream mapping, all the factors affecting throughput time are identified. Based on the expert's opinion eight key factors and one interaction factor is arrived. To check the influence of these factors over the throughput time, Design of Experiments is carried out. Doing experiments in the real production line consumes more time, effort & cost and to minimize this, Simulation model is used. A Simulation model of the whole production Line of the starter motor manufacturing was built in ARENA software and results were analyzed through ANOVA. The significant input factors in the line that affect throughput time are identified and actions are initiated to reduce the throughput time. Top Keywords Lean manufacturing analysis, Design of experiments & Simulation. Top |