The Impact of the Application of Lean Tools for Improvement of Process in a Plastic Company: a case study

Abstract This article is the result of a work developed in plastic products manufacturing plant. The main objective of this project was the implementation of Lean tools in the two main products of this company, the wheel covers and the front bumpers, in order to obtain a reduction in the cycle times, an increased output in the production lines and a reduction in the complains associated to these products. The investigation methodology used was Action Research. This investigation began with the bibliographic review of Lean and the main Lean tools used in this organizational model such as 5S, Visual Management, SMED, Standard Work and OEE. The diagnose was initiated through a detailed description and analysis of the several processes associated with each product. For that, several parameters were analyzed (non-conformities, complains, delivery delays and calculating the OEE values) and the improvement opportunities were identified. For each identified aspect, improvements were proposed trough Lean tools and methodologies such as 5S, Visual Management, SMED and Standard Work. Some improvements also applied to the process had no relation to Lean tools and methodologies. The implementation of the suggested improvement proposals had quite positive impacts such as the 70% reduction of transportation times in the painting production line and the growth of the OEE index in 18% in the injection process, 16% in the painting production line of the Wheel Covers and 17% in the painting production line of the Front Bumpers.