SUNConferences, 29th Annual Conference of SAIIE

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CONTINUOUS PROCESS IMPROVEMENT ON HEAT EXCHANGER PLANT THROUGH VALUE STREAM MAPPING
Mendon Dewa, Kate Perry Lusiba

Last modified: 2018-10-09

Abstract


Lean manufacturing is an optimum approach for the reduction and elimination of waste within an organisation. The case study company is based in South Africa and produces heat exchangers through main processes which include pre-assembly, core building, brazing and final assembly. A plant walkthrough revealed an inefficient portrayed by inventory stacked awaiting final assembly and frequent delays at the brazing furnace as it waited for material from core building. This paper proposes a framework for continuous process improvement through the deployment of value stream mapping. Process analysis was conducted using value stream analysis and it was revealed that operators were not fully utilizing the capacity of the bottleneck workstations. Two instead of one planning points and inefficiency at assembly were identified as root causes of the high work in process level. Furthermore, work in process build-up was caused by the furnace that was run two shifts while the preceding assembly and core building were running three shifts. Recommendations were made for continuous process improvement and a roadmap for reduction of waste was proposed.


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