Lean culture implementation

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Market and competition are forcing manufacturing companies to be more responsive to product variety and more cost-effective. This fact adds more constraints to management teams, and especially when dealing with job-shop type production system operating in batch environment and requiring frequent machine setups. The aim of this research work is to address a specific request from a dynamic manufacturing company, Rulmeca Ltd., specializing in motorized pulleys, conveyors idlers and many other custom-made products. The specific request consists in outlining a solution approach that would help the company in maintaining/improving its performance in terms of minimizing waste and losses and phasing in lean manufacturing culture. Total Productive Maintenance (TPM) has been identified as the most promising as it consists of a holistic approach to equipment maintenance that strives to achieve perfect production (no breakdowns, no small machine stoppages or slow running, no defects, and no accidents). A thorough analysis and evaluation of the current manufacturing practices of our industry partner, Rulmeca Ltd., will be conducted with the aim of implementing a TPM program that creates a shared responsibility for equipment and encourages greater involvement by plant floor workers. In the right environment this can be very effective in improving productivity by increasing up time, reducing cycle times, and eliminating defects.