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PRODUCTIVITY IMPROVEMENT OF HIGHWAY ENGINEERING INDUSTRY BY IMPLEMENTATION OF LEAN SIX SIGMA, TPM, ECRS, AND 5S: A CASE STUDY OF AAA CO., LTD.
Corresponding Author(s) : Piyachat Burawat
Humanities & Social Sciences Reviews,
Vol. 7 No. 5 (2019): September
Abstract
Purpose: The objective of this study is to improve productivity by means of lean six sigma, TPM, ECRS, and 5S in the highway engineering industry. The study was conducted from November 2017 to April 2018 from a case study of AAA Co., Ltd. The data were collected from the managers and supervisors and the problems were analyzed by brainstorming, cause and effect diagram, and Pareto chart. Referring to the results, it was found that production problems occurred from the asphalt process. The majority problem was wet rock and rock sticking to the conveyor belt.
Methodology: Considering the shed, the shed of stone storage could be changed from construction from net or fabric sieve to construction from the metal sheet. Regarding the conveyor belt, the conveyor belt could be changed from conveyor belt without roof to constructed conveyor roof from metal sheet. The messy construction area was improved by 5S. Essential materials and equipment were sorted in construction area, while the other remained materials and equipment were removed to another area.
Main Findings: The findings demonstrated that Lean Six Sigma, ECRS, TPM, and 5S can be seen as an effective technique that can reduce waste and improve business performance which can be applied in any industry as well as any size of the company. It very well may be viewed as the advancement of the improvement strategies among the representatives and as a preparation technique for the workers. The discoveries illustrated, in any case, that there are snags in the viable execution of the improved methods for any improvement reason.
Implications/Applications: The findings confirmed that it can be applied in both manufacturing and services business. Due to the lower resource investment, it can be implemented in any company like small, medium, and large company.
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- Abdurrahaman, D. T., & Osman, Z. (2017). Development of conceptual framework for Nigerian generation Y-ers’ purchase intention and response towards indigenous celebrity-endorsed products: A PLS-SEM Study on Selected Mobile Service Providers in Nigeria. Journal of Administrative and Business Studies, 3(1), 49-59. https://doi.org/10.20474/jabs-3.1.6 DOI: https://doi.org/10.20474/jabs-3.1.6
- Anjani, B. R., & Baihaqi, I. (2018). Comparative analysis of financial Production Sharing Contract (PSC) cost recovery with PSC gross split: Case study in one of the contractor SKK Migas. Journal of Administrative and Business Studies, 4(2), 65-80. https://doi.org/10.20474/jabs-4.2.2 DOI: https://doi.org/10.20474/jabs-4.2.2
- Ayuningrat, M. P., Noermijati., & Hadiwidjojo, D. (2016). Green product innovation’s effect on firm performance of managerial environmental concern and green communication. Journal of Administrative and Business Studies, 2(2), 56-63. https://doi.org/10.20474/jabs-2.2.1 DOI: https://doi.org/10.20474/jabs-2.2.1
- Dasig, Jr, D. (2017). A frontier in organizational and business process innovation in service management through lean six sigma Kaizen project implementation. Journal of Administrative and Business Studies, 3(6), 263-283. https://doi.org/10.20474/jabs-3.6.2 DOI: https://doi.org/10.20474/jabs-3.6.2
- Drucker, P. F. (1999). Management challenges for the 21st century. New York, NY: Harper Collins.
- Eze, I. O. (2017). Corporate governance mechanisms and earnings management in Nigerian food product companies. Journal of Administrative and Business Studies, 3(1), 1-9. https://doi.org/10.20474/jabs-3.1.1 DOI: https://doi.org/10.20474/jabs-3.1.1
- George, M. L. (2002). Lean six sigma: Combining six sigma quality with lean speed. New York, NY: McGraw-Hill.
- Heizer, J., & Render, B. (2014). Operations management (11th ed.). London, UK: Pearson Education Limited.
- Karkoszka, T., & Szewieczek. D. (2007). Risk of the processes in the aspect of quality, natural environment and occupational safety. Journal of Achievements in Materials and Manufacturing Engineering, 20, 539-542.
- Kasemset, C., Boonmee, C., & Khuntaporn, P. (2016). Application of MFCA and ECRS in waste reduction: A case study of electronic parts factory. Proceedings of the 2016 International Conference on Industrial Engineering and Operations Management, Kuala Lumpur, Malaysia.
- Khamis, N., Ab Rahman, M. N., Jamaludin, K. R., Ismail, A. R., Ghani, J. A., & Zulkifli, R. (2009). Development of 5S practice checklist for manufacturing industry. Proceedings of the World Congress on Engineering 2009, July 1 - 3, London, U.K.
- King, J. M. (2016). Dubai wins: A content analysis of global media coverage of the 2020 world exposition bidding process using nation branding theory. International Journal of Business and Administrative Studies, 2(6), 201-211. https://doi.org/10.20469/ijbas.2.10005-6 DOI: https://doi.org/10.20469/ijbas.2.10005-6
- Lammon, D. (2010). An examination of productivity in the utility industry (Master thesis). Empire State College, State University of New York, New York, NY.
- Mogensen, A. H. (1932). Common sense applied to motion and time study. New York, NY: Factory and Industrial Management, McGraw-Hill book company, Inc.
- Osada, T. (1991). 5S’s: five keys to a total quality control environment. Tokyo: Asia Productivity Organization.
- Panti, E., Gempes, M., & Gloria, P. (2018). The mediating effect of risk management strategies on the relationship between attitude constructs and sustainability of banana production in Southern Philippines. International Journal of Business and Administrative Studies, 4(2), 68-77. https://doi.org/10.20469/ijbas.4.10004-2 DOI: https://doi.org/10.20469/ijbas.4.10004-2
- Prokopenko, J. (1987). Productivity management: A practical hand book. Geneva: International Labour Office.
- Riza, A.R. (2011). Methodology development for calculating productivity and its losses to determine optimization regime in assembly line (Master thesis). Malaysia: School of Manufacturing Engineering, University of Malaysia Perlis.
- Ruch, W. A. (1994). Measuring and managing individual productivity. In H. H., Douglas (Eds.), Organizational linkages: understanding the productivity paradox (pp. 105-130). Washington, D.C, WA: National Academy Press.
- Sharma, R., & Singh, J. (2015). Impact of implementing Japanese 5S practices on total productive maintenance. International Journal of Current Engineering and Technology, 5(2), 818-825.
- Snee, R. D. (2010). Lean six sigma: getting better all the time. International Journal of Lean Six Sigma, 1(1), 9-29. https://doi.org/10.1108/20401461011033130 DOI: https://doi.org/10.1108/20401461011033130
- Taorid, A. A. (2016). Enhancing business process through research. International Journal of Business and Administrative Studies, 2(3), 62-69. https://doi.org/10.20469/ijbas.2.10002-3 DOI: https://doi.org/10.20469/ijbas.2.10002-3
- Titu, M. A., Oprean, C., & Grecu, D. (2010). Applying the Kaizen method and the 5S technique in the activity of post-sale services in the knowledge-based organization. Proceedings of the International Multi Conference of Engineers and Computer Scientists, 2010, Vol III, IMECS 2010, March 17-19, Hong Kong.
- Tsuchiya, S. (1992). Quality maintenance: Zero defects through equipment management. Cambridge, MA: Productivity Press.
References
Abdurrahaman, D. T., & Osman, Z. (2017). Development of conceptual framework for Nigerian generation Y-ers’ purchase intention and response towards indigenous celebrity-endorsed products: A PLS-SEM Study on Selected Mobile Service Providers in Nigeria. Journal of Administrative and Business Studies, 3(1), 49-59. https://doi.org/10.20474/jabs-3.1.6 DOI: https://doi.org/10.20474/jabs-3.1.6
Anjani, B. R., & Baihaqi, I. (2018). Comparative analysis of financial Production Sharing Contract (PSC) cost recovery with PSC gross split: Case study in one of the contractor SKK Migas. Journal of Administrative and Business Studies, 4(2), 65-80. https://doi.org/10.20474/jabs-4.2.2 DOI: https://doi.org/10.20474/jabs-4.2.2
Ayuningrat, M. P., Noermijati., & Hadiwidjojo, D. (2016). Green product innovation’s effect on firm performance of managerial environmental concern and green communication. Journal of Administrative and Business Studies, 2(2), 56-63. https://doi.org/10.20474/jabs-2.2.1 DOI: https://doi.org/10.20474/jabs-2.2.1
Dasig, Jr, D. (2017). A frontier in organizational and business process innovation in service management through lean six sigma Kaizen project implementation. Journal of Administrative and Business Studies, 3(6), 263-283. https://doi.org/10.20474/jabs-3.6.2 DOI: https://doi.org/10.20474/jabs-3.6.2
Drucker, P. F. (1999). Management challenges for the 21st century. New York, NY: Harper Collins.
Eze, I. O. (2017). Corporate governance mechanisms and earnings management in Nigerian food product companies. Journal of Administrative and Business Studies, 3(1), 1-9. https://doi.org/10.20474/jabs-3.1.1 DOI: https://doi.org/10.20474/jabs-3.1.1
George, M. L. (2002). Lean six sigma: Combining six sigma quality with lean speed. New York, NY: McGraw-Hill.
Heizer, J., & Render, B. (2014). Operations management (11th ed.). London, UK: Pearson Education Limited.
Karkoszka, T., & Szewieczek. D. (2007). Risk of the processes in the aspect of quality, natural environment and occupational safety. Journal of Achievements in Materials and Manufacturing Engineering, 20, 539-542.
Kasemset, C., Boonmee, C., & Khuntaporn, P. (2016). Application of MFCA and ECRS in waste reduction: A case study of electronic parts factory. Proceedings of the 2016 International Conference on Industrial Engineering and Operations Management, Kuala Lumpur, Malaysia.
Khamis, N., Ab Rahman, M. N., Jamaludin, K. R., Ismail, A. R., Ghani, J. A., & Zulkifli, R. (2009). Development of 5S practice checklist for manufacturing industry. Proceedings of the World Congress on Engineering 2009, July 1 - 3, London, U.K.
King, J. M. (2016). Dubai wins: A content analysis of global media coverage of the 2020 world exposition bidding process using nation branding theory. International Journal of Business and Administrative Studies, 2(6), 201-211. https://doi.org/10.20469/ijbas.2.10005-6 DOI: https://doi.org/10.20469/ijbas.2.10005-6
Lammon, D. (2010). An examination of productivity in the utility industry (Master thesis). Empire State College, State University of New York, New York, NY.
Mogensen, A. H. (1932). Common sense applied to motion and time study. New York, NY: Factory and Industrial Management, McGraw-Hill book company, Inc.
Osada, T. (1991). 5S’s: five keys to a total quality control environment. Tokyo: Asia Productivity Organization.
Panti, E., Gempes, M., & Gloria, P. (2018). The mediating effect of risk management strategies on the relationship between attitude constructs and sustainability of banana production in Southern Philippines. International Journal of Business and Administrative Studies, 4(2), 68-77. https://doi.org/10.20469/ijbas.4.10004-2 DOI: https://doi.org/10.20469/ijbas.4.10004-2
Prokopenko, J. (1987). Productivity management: A practical hand book. Geneva: International Labour Office.
Riza, A.R. (2011). Methodology development for calculating productivity and its losses to determine optimization regime in assembly line (Master thesis). Malaysia: School of Manufacturing Engineering, University of Malaysia Perlis.
Ruch, W. A. (1994). Measuring and managing individual productivity. In H. H., Douglas (Eds.), Organizational linkages: understanding the productivity paradox (pp. 105-130). Washington, D.C, WA: National Academy Press.
Sharma, R., & Singh, J. (2015). Impact of implementing Japanese 5S practices on total productive maintenance. International Journal of Current Engineering and Technology, 5(2), 818-825.
Snee, R. D. (2010). Lean six sigma: getting better all the time. International Journal of Lean Six Sigma, 1(1), 9-29. https://doi.org/10.1108/20401461011033130 DOI: https://doi.org/10.1108/20401461011033130
Taorid, A. A. (2016). Enhancing business process through research. International Journal of Business and Administrative Studies, 2(3), 62-69. https://doi.org/10.20469/ijbas.2.10002-3 DOI: https://doi.org/10.20469/ijbas.2.10002-3
Titu, M. A., Oprean, C., & Grecu, D. (2010). Applying the Kaizen method and the 5S technique in the activity of post-sale services in the knowledge-based organization. Proceedings of the International Multi Conference of Engineers and Computer Scientists, 2010, Vol III, IMECS 2010, March 17-19, Hong Kong.
Tsuchiya, S. (1992). Quality maintenance: Zero defects through equipment management. Cambridge, MA: Productivity Press.