IMPROVING MANUFACTURING PROCESS

THROUGH LEAN IMPLEMENTATION IN

SMALL SCALE MANUFACTURING
WORKSHOP IN KUALA LANGAT
FAIZUN BINTI NASARUDIN
B071410617

SUPERVISOR:
MOHD FARIDUDDIN BIN
MUKHTAR

CO. SUPERVISOR:
MOHD SOUFHWEE BIN ABD
RAHMAN
List of Contents
1.0 Introduction
1.1 Research Background
1.2 Problem Statement
1.3 Research Objectives
1.4 Work Scope
1.5 Significant of Study
2.0 Literature Review
2.1 Quality
2.2 Lean Manufacturing
2.3 Lean Waste
2.4 Lean Tools and Techniques

3.0 Methodology
3.1 Research Methodology
3.2 Pre Post Survey
3.3 Arena Analysis
 1.0 Introduction

1.1 Research Background

1.2 Problem Statement
1.3 Research Objectives
1.4 Work Scope
1.5 Significant of Study
1.1 Research Background

Small Scale Industry

Plays an important role in economy

Contributes more than 50% of the industrial

production in value addition terms

Demanding product of high quality and low

cost

Aimed to reduce all types of waste

(Specifically waste in motion and over
1.2 Problem Statement

Manufacturing workshop been

facing problem of producing a lot
of waste (motion and over
processing) without noticing it

Non-values added jobs will cause

loss of profit to the company as
well as to the customers
Amrysha
Resource
s Sdn.
Bhd.

Improper
arrangeme
nt of tools

Unorganiz
ed
workstatio
n

Improper
productio
n line
1.3 Research Objectives

The objective of this study are as

follows:

To study the waste of motion and over

processing in the manufacturing
workshop

To implement lean manufacturing tools

at the manufacturing workshop

To analyze the result of the lean tools

1.4 Work Scope

Scope of this study are:

Focus on eliminate the waste in motion

and over processing that occur in the
workshop

Find root of the waste in motion and over

processing in the company and suggest
the solution to overcome it
1.5 Significant of Study

Improve quality to stay

competitive in the marketplace

Eliminate waste in any activity

that consume time, space or
resources

Reduce time in order to minimize

cost
 2.0 Literature Review

2.1 Quality
2.2 Lean Manufacturing
2.3 Lean Wastes (MUDA)
2.4 Lean Tools and Techniques
2.1 Quality

Quality in manufacturing is a measure of excellence

or a state of being free from defects, deficiencies
and significant variations

Figure 2.1: 8 Dimension of Quality (Garvin, 1986)

The definition of quality
is Uniformity around
a target value
(Taguchi, 1992)
2.2 Lean Manufacturing
Womack and Jones (1996) explain that lean thinking is
more than just a technique, it is a deep-rooted culture
within the workplace that makes everyone in the
organization continually improve operations.

Figure 2.2: 8 Dimension of Quality (Garvin, 1986)

 Lean manufacturing is a Japanese method focused on 3Ms

Muda specifically focuses on activities to be eliminated

Figure 2.3: The 3Ms

2.3 Lean Waste (MUDA)
 Figure 2.4: Value Added and Non-Value Added Activities

"The seven wastes" is a tool to further classify

muda and was originally developed by Toyotas
Chief Engineer Taiichi Ohno
2.4 Lean Tools and
Techniques
Over
processing

Motion
 3.0 Methodology

3.1 Research Methodology

3.2 Pre Post Survey
3.3 Arena Analysis
3.1 Research Methodology
3.2 Pre Post Survey

Pre and post survey is used to gain

information from the workers in the Amrysha
Resources Sdn. Bhd

Focused on two types of data which is about

the motion and over processing waste

Pre-survey is distributed and collected before

the suggestion and improvement is made

Post survey is then distributed and data will

be collected and analysed again
3.3 Arena Analysis

Arena is a discrete event simulation and

automation software developed by Systems
Modeling

Statistical data, such as cycle time and work

in progress (WIP) levels, can be recorded and
made output as reports

Simulation will be made to see if the lean

implementation tool used is effective or not.
Gantt Chart
Thank You