Comprehensive application of operational excellence techniques with discrete event simulation for productive improvement in a ceramic industry
Keywords:
TOC, Lean, Six sigma, Discrete event simulation, FlexSim®Abstract
Currently, productive organizations face an era of constant challenges related to the adaptation of their processes to the new productive paradigm of intelligent industries, globalized markets, high competitiveness and product customization. Under this scenario, operational excellence methodologies integrated with digital twin technologies play a leading role in improving business performance and generating competitive advantages.
The present work proposes as a central axis of research the joint application of the TLS model (TOC, Lean, Six Sigma) with discrete event simulation techniques and experimental designs, as a basis to generate an improvement in the productive capacity of a porcelain tile line. in a ceramic industry, located in the province of Buenos Aires.
The methodology used for its development consists of four (4) main phases. A first phase of characterization of the process and quantification of resources for the development of a conceptual model. A second phase of development and validation of the computational model, using FlexSim® as a simulation tool. A third phase of diagnosis, where through the VSM technique and the theory of restrictions, the cooking operation was identified as the bottleneck of the system. And a last phase, analysis, in which, through a unifactorial experiment design, different scenarios were evaluated to enhance the productive capacity of the line by implementing changes in the current structure of the furnace.
Downloads
References
Ahmed, S. (2019). Integrating DMAIC approach of Lean Six Sigma and theory of constraints toward quality improvement in healthcare. Reviews on Environmental Health. https://doi.org/10.1515/reveh-2019-0003
Barra Montevechi, J. A., Leal, F., De Pinho, A. F., Da Silva Costa, R. F., Moura De Oliveira, M. L., & Faustino Da Silva, A. L. (2010). Conceptual modeling in simulation projects by mean adapted IDEF: An application in a Brazilian tech company. Proceedings - Winter Simulation Conference. https://doi.org/10.1109/WSC.2010.5678908
Buer, S. V., Strandhagen, J. O., & Chan, F. T. S. (2018). The link between industry 4.0 and lean manufacturing: Mapping current research and establishing a research agenda. International Journal of Production Research, 56(8). https://doi.org/10.1080/00207543.2018.1442945
Cai, H., & Jia, J. (2019). Using Discrete Event Simulation (DES) To Support Performance-Driven Healthcare Design. Health Environments Research and Design Journal, 12(3). https://doi.org/10.1177/1937586718801910
Chauhan, G., & Singh, T. P. (2012). Measuring parameters of lean manufacturing realization. Measuring Business Excellence, 16(3). https://doi.org/10.1108/13683041211257411
Chen, Y. L., & Weng, C. H. (2009). Mining fuzzy association rules from questionnaire data. Knowledge-Based Systems. https://doi.org/10.1016/j.knosys.2008.06.003
Cortes, H., Daaboul, J., Le Duigou, J., & Eynard, B. (2016). Strategic Lean Management: Integration of operational Performance Indicators for strategic Lean management. IFAC-PapersOnLine, 49(12). https://doi.org/10.1016/j.ifacol.2016.07.551
Dias, R. M. F., Silva, L. D., & Tenera, A. (2019). Application of a proposed TLS model in a Lean Productive System. Independent Journal of Management & Production, 10(1). https://doi.org/10.14807/ijmp.v10i1.830
Dogan, O., & Gurcan, O. F. (2018). Data perspective of lean six sigma in industry 4.0 era: A guide to improve quality. Proceedings of the International Conference on Industrial Engineering and Operations Management, 2018(JUL).
Drohomeretski, E., Gouvea Da Costa, S. E., Pinheiro De Lima, E., & Garbuio, P. A. D. R. (2014). Lean, six sigma and lean six sigma: An analysis based on operations strategy. International Journal of Production Research, 52(3). https://doi.org/10.1080/00207543.2013.842015
Ehie, I., & Sheu, C. (2005). Integrating six sigma and theory of constraints for continuous improvement: A case study. Journal of Manufacturing Technology Management, 16(5). https://doi.org/10.1108/17410380510600518
Furian, N., O’Sullivan, M., Walker, C., Vössner, S., & Neubacher, D. (2015). A conceptual modeling framework for discrete event simulation using hierarchical control structures. Simulation Modelling Practice and Theory, 56. https://doi.org/10.1016/j.simpat.2015.04.004
Garza-Reyes, J. A., Villarreal, B., Kumar, V., & Diaz-Ramirez, J. (2019). A lean-TOC approach for improving Emergency Medical Services (EMS) transport and logistics operations. International Journal of Logistics Research and Applications, 22(3). https://doi.org/10.1080/13675567.2018.1513997
Goldratt, E. M., & Cox, J. (2012). The Goal: A Process of Ongoing Improvement (North River PR Inc (ed.); Revised).
Jevgeni, S., Eduard, S., & Roman, Z. (2015). Framework for continuous improvement of production processes and product throughput. Procedia Engineering, 100(January). https://doi.org/10.1016/j.proeng.2015.01.398
Kang, H. S., Lee, J. Y., Choi, S., Kim, H., Park, J. H., Son, J. Y., Kim, B. H., & Noh, S. Do. (2016). Smart manufacturing: Past research, present findings, and future directions. International Journal of Precision Engineering and Manufacturing - Green Technology, 3(1). https://doi.org/10.1007/s40684-016-0015-5
Laureani, A., & Antony, J. (2019). Leadership and Lean Six Sigma: a systematic literature review. In Total Quality Management and Business Excellence (Vol. 30, Issues 1–2). https://doi.org/10.1080/14783363.2017.1288565
Leal, F., Almeida, D. A. de, & Montevechi, J. A. B. (2008). Uma Proposta de Técnica de Modelagem Conceitual para a Simulação através de Elementos do IDEF. In: Simpósio Brasileiro de Pesquisa Operacional (SBPO), 40, 2008, João Pessoa.
Miluska Aylin, A. Y. (2016). Integración Lean Manufacturing y Seis Sigma. Aplicación pymes. 86. https://riunet.upv.es/bitstream/handle/10251/72921/TFM Integración Lean Seis Sigma_ Miluska Añaguari.pdf?sequence=3&isAllowed=y
Mourtzis, D., Doukas, M., & Bernidaki, D. (2014). Simulation in manufacturing: Review and challenges. Procedia CIRP, 25(C). https://doi.org/10.1016/j.procir.2014.10.032
Pacheco, D. A. de J., Pergher, I., Antunes Junior, J. A. V., & Roehe Vaccaro, G. L. (2019). Exploring the integration between Lean and the Theory of Constraints in Operations Management. International Journal of Lean Six Sigma, 10(3). https://doi.org/10.1108/IJLSS-08-2017-0095
Prakash, S., Kumar, S., Soni, G., Mahto, R. V., & Pandey, N. (2022). A decade of the international journal of lean six sigma: bibliometric overview. In International Journal of Lean Six Sigma (Vol. 13, Issue 2). https://doi.org/10.1108/IJLSS-12-2020-0219
Rajini, J., Nagaraju, D., & Narayanan, S. (2018). Integration of lean, Six Sigma and theory of constraints for productivity improvement of mining industry. International Journal of Productivity and Quality Management, 24(3). https://doi.org/10.1504/IJPQM.2018.092986
Ramírez Pérez, J. F., López Torres, V. G., Hernández Castillo, S. A., & Morejón Valdés, M. (2021). LEAN SIX SIGMA E INDUSTRIA 4.0, UNA REVISIÓN DESDE LA ADMINISTRACIÓN DE OPERACIONES PARA LA MEJORA CONTINUA DE LAS ORGANIZACIONES. UNESUM-Ciencias. Revista Científica Multidisciplinaria. ISSN 2602-8166, 5(4). https://doi.org/10.47230/unesum-ciencias.v5.n4.2021.584
Santos, C. H. dos, de Queiroz, J. A., Leal, F., & Montevechi, J. A. B. (2022). Use of simulation in the industry 4.0 context: Creation of a Digital Twin to optimise decision making on non-automated process. Journal of Simulation, 16(3), 284–297. https://doi.org/10.1080/17477778.2020.1811172
Solís Granda, L., Pérez Manzo, O., Burgos Villamar, I., & Villao Viteri, J. (2017). Uso de la Administración de Operaciones en las Mipymes. Revista Científica y Tecnológica UPSE, 4(1). https://doi.org/10.26423/rctu.v4i1.243
Sukwadi, R., Felicia, Y., & Muafi. (2021). TOC, lean, and six sigma: An integrated model to increase the productivity of the textile industry. Journal of Mechanical Engineering Research and Developments, 44(1).
Tampubolon, S., & Purba, H. H. (2021). Lean six sigma implementation, a systematic literature review. In International Journal of Production Management and Engineering (Vol. 9, Issue 2). https://doi.org/10.4995/IJPME.2021.14561
Tortorella, G. L., Fetterman, D., Giglio, R., & Borges, G. A. (2018). Implementação Da Produção Enxuta E Indústria 4.0 Em Empresas Brasileiras De Manufatura. Revista Empreender e Inovar, 1(1).
Tyagi, S., Cai, X., Yang, K., & Chambers, T. (2015). Lean tools and methods to support efficient knowledge creation. International Journal of Information Management, 35(2). https://doi.org/10.1016/j.ijinfomgt.2014.12.007
Ynzunza, C., Izar, J., Bocarando, J., Aguilar, F., & Larios, M. (2017). El Entorno de la Industria 4.0: Implicaciones y Perspectivas Futuras Implications and Perspectives of Industry 4.0. Conciencia Tecnológica, 8.
