Skip to main content

LUP Student Papers

LUND UNIVERSITY LIBRARIES

Improving Materials Supply Processes to Assembly Lines Through Toyota Production System and Lean Manufacturing

Östlund, Patrik LU (2020) MTTM05 20192
Engineering Logistics
Department of Industrial Management and Logistics
Abstract
Purpose – TePe Munhygienprodukter AB (TePe) is moving the production facility designated their toothbrushes as part of their expansion phase. Not only do they face challenges due to a two-floor production, but also do they face efficiency and safety challenges in their materials flow. The purpose of this paper is, therefore, to construct recommendations on improving TePe’s materials supply processes to assembly lines through Toyota production system (TPS) and Lean manufacturing (Lean).

Design/methodology/approach – A constructive research approach is conducted to develop problem-solving constructs for TePe in regards to abovementioned challenges. In addition, a dual case study is conducted to find gaps between TePe’s actual and... (More)
Purpose – TePe Munhygienprodukter AB (TePe) is moving the production facility designated their toothbrushes as part of their expansion phase. Not only do they face challenges due to a two-floor production, but also do they face efficiency and safety challenges in their materials flow. The purpose of this paper is, therefore, to construct recommendations on improving TePe’s materials supply processes to assembly lines through Toyota production system (TPS) and Lean manufacturing (Lean).

Design/methodology/approach – A constructive research approach is conducted to develop problem-solving constructs for TePe in regards to abovementioned challenges. In addition, a dual case study is conducted to find gaps between TePe’s actual and potential performance. A comprehensive theoretical framework of TPS/Lean bridges case-specific practice and theory.

Findings – This research has found seven constructs for TePe to mitigate many of the challenges they face, and improve their overall flow efficiency through TPS/Lean, namely: setup time and batch size reductions, layout changes, and an implementation of a supermarket, a Kanban system, a 5S initiative and managerial principles (i.e. Genchi genbutsu, Visual management, Kaizen, 5 Whys and a re-evaluation of strategies). The company can save 0.74 MSEK yearly in inventory holding costs through a setup time and batch size reduction with 57 and 50 per cent, respectively. The constructs provide a clean, structured replenishment system, eliminating the problematic safety hazards altogether. There is also a chain of indirect benefits from all seven constructs. Therefore, management is vital for building and fostering a new culture of continuous improvements and employee engagement.

Originality/value – This paper contributes to both academia and practice by applying the constructive research approach on materials flow, tailored for a manufacturing firm. Moreover, an explicit comparison of Lean maturity models is conducted, by this paper’s author not found elsewhere, and a new TPS/Lean maturity model is introduced. (Less)
Please use this url to cite or link to this publication:
author
Östlund, Patrik LU
supervisor
organization
alternative title
Improving Materials Supply Processes to Assembly Lines Through TPS and Lean
course
MTTM05 20192
year
type
H2 - Master's Degree (Two Years)
subject
keywords
Lean manufacturing, Toyota production system, Operations management, Flow efficiency, Continuous improvements, Setup time reduction, Kanban system, Constructive research approach
report number
5926
language
English
id
9024451
date added to LUP
2020-08-18 13:35:41
date last changed
2020-08-18 13:35:41
@misc{9024451,
  abstract     = {{Purpose – TePe Munhygienprodukter AB (TePe) is moving the production facility designated their toothbrushes as part of their expansion phase. Not only do they face challenges due to a two-floor production, but also do they face efficiency and safety challenges in their materials flow. The purpose of this paper is, therefore, to construct recommendations on improving TePe’s materials supply processes to assembly lines through Toyota production system (TPS) and Lean manufacturing (Lean).

Design/methodology/approach – A constructive research approach is conducted to develop problem-solving constructs for TePe in regards to abovementioned challenges. In addition, a dual case study is conducted to find gaps between TePe’s actual and potential performance. A comprehensive theoretical framework of TPS/Lean bridges case-specific practice and theory.

Findings – This research has found seven constructs for TePe to mitigate many of the challenges they face, and improve their overall flow efficiency through TPS/Lean, namely: setup time and batch size reductions, layout changes, and an implementation of a supermarket, a Kanban system, a 5S initiative and managerial principles (i.e. Genchi genbutsu, Visual management, Kaizen, 5 Whys and a re-evaluation of strategies). The company can save 0.74 MSEK yearly in inventory holding costs through a setup time and batch size reduction with 57 and 50 per cent, respectively. The constructs provide a clean, structured replenishment system, eliminating the problematic safety hazards altogether. There is also a chain of indirect benefits from all seven constructs. Therefore, management is vital for building and fostering a new culture of continuous improvements and employee engagement.

Originality/value – This paper contributes to both academia and practice by applying the constructive research approach on materials flow, tailored for a manufacturing firm. Moreover, an explicit comparison of Lean maturity models is conducted, by this paper’s author not found elsewhere, and a new TPS/Lean maturity model is introduced.}},
  author       = {{Östlund, Patrik}},
  language     = {{eng}},
  note         = {{Student Paper}},
  title        = {{Improving Materials Supply Processes to Assembly Lines Through Toyota Production System and Lean Manufacturing}},
  year         = {{2020}},
}