Lean Manufacturing Case Study [PDF]

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Managing Lean Manufacturing in Oilfield Equipment Industry Case Study



Research Problem 



Operational objectives are set by top management and Lean Manufacturing is defined as a method of obtaining those objectives.



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Operational management is giving a set of lean principles but no way of establishing how to apply them or implement them.



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Operational management is often left with the task of defining the objectives of deploying lean principles.



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Materials Handling is often one of the key sources of waste in many companies.



Research Objectives 



The objectives of this study are: 



To develop a methodology that can be used to assist in determining management objectives of lean manufacturing.



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To show how this methodology can be used to assist in eliminating waste in material handling processes. Case study will be limited to a single cell



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Research Approach 



Review literature on lean manufacturing, its implementation and material handling.



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Overview of lean manufacturing and management objectives



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Development of the Methodology



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Case Study: Hughes Christensen



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Conclusion and Direction for Future Research



Methodology 



Management Input



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Lean Assessment Development of Lean Strategy Definition of Lean Objectives Selection of Lean Tools Solution Implementation



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Case Study 



Hughes Christensen 



Oil Services – Leading Drill Bit Manufacturer 



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Over 30% of Current Market Share – Market Leader



Lean Manufacturing  



Current Implementation Deployment in ‘Diamond Products’ Lafayette Manufacturing Facility



Case Study 



Lean Manufacturing 



Lean Manufacturing Mandated



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Lean Tool Kit Provided



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Addressing Material Handling in Diamond Products Remains an Issue



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Management Objectives of Lean Manufacturing in Regards to Materials Handling Not Defined by Top Management



Research Process



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Research Process



Case Study 



Hughes Christensen 



Area of Opportunity 



Crown Machining Cell – Thread Connection for API Connection Shank Machined and Shank Connected.



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Problem Area – Material Handling of Connection Stock.



Performance Evaluation 



Performance Measures 



KPI Values Linked to Objectives of both Lean Manufacturing and Operational Goals.



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Dependent upon needs and goals by Management 



(e.g. Incident Report, Productivity, Through Put, etc…)



Business unit and operational group goals



Cell Layout



Material handling value stream map – crown machine cell



Value stream map data – current state map



Lean manufacturing tools



Proposed Staging Device



Layout after lean implementation



Future state value stream map – crown machine cell



Comparison of current state and future state maps



Conclusion   



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Material Handling Layout and Flowchart Methodology VSM – Current State Performance Measures- Time; #Activities Lean Tools VSM – Future State %Savings