Improving Productivity and Quality of a Transformer Production Line by Applying Lean Manufacturing Principles
The objective of this research is to study a production line and apply Lean principles and tools to resolve quality problems and improve productivity. The production line selected for the study is the medium voltage line in ABB Group's Medium Voltage Products facility located in Pinetops, North Carolina. The production line was unable to achieve the desired production rate due to several reasons, including flow, work methods, constraints, rework, scrap, inventory, and storage arrangement. One of the major improvements made during the project was to study the production flow data and balance the assembly process. After balancing the assembly line, single-piece flow was implemented to increase efficiency. Other major improvements made were to the Hydrophobic Cycloaliphatic Epoxy casting process and the winding process by reducing changeover times, and reducing worker idle times. Some of the Lean techniques that were used during the project were: value stream mapping, process flow diagrams, standardizing work procedures, 5 S, and visual management. These techniques were used to reduce and eliminate all waste surrounding the process. A key aspect of the study was to document all phases of the project and challenges faced during the implementation. This was done so that other companies with similar operations will benefit from the data and knowledge gained throughout the life of the project. There is a supplement file that contains an enlarged version of the following diagrams: Current State Map, Current State Map with Kaizen Improvements, Future State Map, and Brainstorming Cloud.
Johnson, Robert. (January 2015). Improving Productivity and Quality of a Transformer Production Line by Applying Lean Manufacturing Principles (Master's Thesis, East Carolina University). Retrieved from the Scholarship. (http://hdl.handle.net/10342/4950.)
Johnson, Robert. Improving Productivity and Quality of a Transformer Production Line by Applying Lean Manufacturing Principles. Master's Thesis. East Carolina University, January 2015. The Scholarship. http://hdl.handle.net/10342/4950. February 20, 2019.
Johnson, Robert, “Improving Productivity and Quality of a Transformer Production Line by Applying Lean Manufacturing Principles” (Master's Thesis., East Carolina University, January 2015).
Johnson, Robert. Improving Productivity and Quality of a Transformer Production Line by Applying Lean Manufacturing Principles [Master's Thesis]. Greenville, NC: East Carolina University; January 2015.
East Carolina University