Improving the Packaging Process of a Textile Company with Lean Production, Time Study and REBA Analysis

Year 2022, Volume: 7 Issue: 2, 499 - 521, 16.01.2023

Dilara Muhacır Muhammed İdris Aktaş Eren Özceylan

https://doi.org/10.26650/JTL.2022.1088652

Abstract

Today, companies have to use their resources in the most effective and efficient way in order to effectively meet the increasing competition and changing demands of the customers. Among prominent methods, especially in production, are lean manufacturing techniques, time studies, and ergonomic assessments, alongside being frequently encountered methods. Within the scope of this study, value stream mapping (VSM), time study, and Rapid Entire Body Assessment (REBA) methods were used in order to reach the desired daily shipment amounts using the resources efficiently in the packaging area of the Boyar Kimya textile company, Gaziantep. Firstly, the standard time of the operations was determined by the time study method. The time study method was carried out with the ProTimeEstimation program. Afterwards, the most produced product was selected, the value-adding (VA) and non- value-adding (NVA) operations in the packaging department were determined in detail, and the future state map was created by finding methods to reduce or eliminate NVA operations. The ergonomic evaluation of the working performance of the operators in the packaging department was made with the REBA method. As a result of each method, it has been observed that with the proposed improvements the daily shipment increased dramatically, and the risk levels of the operators decreased.

Keywords

Packaging process, yarn bobbin, time study, value stream mapping, REBA.

References

• Başak, E.E., Yılmaz, I.S., Deniz, N. (2019). A lean manufacturing implementation in an industrial product manufacturer. Journal of Industrial Engineering, 30 (3), 157–172.
• Behnam, D., Ayough, A., Mirghaderi, S.H. (2018). Value stream mapping approach and analytical network process to identify and prioritize production system’s Mudas (case study: natural fibre clothing manufacturing company). Journal of the Textile Institute, 109 (1), 64–72.
• Bhamu, J., Sangwan, K. (2014). Lean manufacturing: Literature review and research issues. International Journal of Operations & Production Management, 34, 876–940.
• Birgün, S., Gülen, K.G., Özkan, K. (2006). Yalın üretime geçiş sürecinde değer akişi haritalama tekniğinin kullanilmasi: imalat sektöründe bir uygulama. İstanbul Ticaret Üniversitesi Fen Bilimleri Dergisi, 5 (9), 47–59.
• Dogan, N.O., Kama, A. (2021). Eliminating non-value-added activities in supply chain: A value stream mapping case study in the manufacturing sector. Niğde Ömer Halisdemir University Journal of Engineering Sciences, 10 (1): 91–99.
• Emir, S., Akyildiz, M., Eker, C., Tufekci, S., Derici, M., Ocaktan, D. (2019). Ergonomıc risk analysis of employees working in the packaging department. Ergonomics, 2 (2), 126–130.
• Esen, H., Fığlalı, N. (2013). Çalışma duruşu analiz yöntemleri ve çalışma duruşunun kas- iskelet sistemi rahatsızlıklarına etkileri. Sakarya Üniversitesi Fen Bilimleri Dergisi, 17 (1), 41–51.
• Gajšek, B., Šinko, S., Kramberger, T., Butlewski, M., Özceylan, E., Đukić, G. (2021). Towards productive and ergonomic order picking: a multi-objective modeling approach. Applied Sciences, 11, 4179.
• Goren, H.G. (2017). Value stream mapping and simulation for lean manufacturing: A case study in furniture industry. Pamukkale University Journal of Engineering Sciences, 23 (4), 462–469.
• Gunduz, F.F., Gunduz, S., Dolekoglu, C.O. (2018). Cluster analysis of the EU countries in which Turkey has
• textile trade. International Journal of Economics and Financial Issues, 8 (5), 332–341.
• Hita-Gutiérrez, M., Galain, M., Perez, M., Ferre A. (2020). An overview of REBA method applications in the World. International Journal of Environmental Research and Public Health, 17 (8), 2635.
• Hignett, S., McAtamney, L. (2000). Rapid entire body assessment (REBA). Applied Ergonomics, 31 (2), 201–205.
• Hodge, G.L., Ross, K.G., Joines, J.A., Thoney, K. (2011). Adapting lean manufacturing principles to the textile industry. Production Planning & Control, 22 (3), 237–247.
• Kee, D. (2022). Systematic comparison of OWAS, RULA, and REBA based on a literature review. International Journal of Environmental Research and Public Health, 19, 595.
• Korkmaz, İ.H., Alsu, E., Özceylan, E., Weber, G.W. (2020). Job analysis and time study in logistic activities: A case study in packing and loading processes. Central European Journal of Operations Research, 28, 733–760.
• Lukodono, R.P., Ulfa, S.K. (2017). Determination of standard time in packaging processing using stopwatch time study to find output standard. Journal of Engineering and Management Industrial System, 5 (2), 87–94.
• Rohac, T, Januska, M. (2015). Value stream mapping demonstration on a real case study. Procedia Engineering, 100, 520–529.
• Sevimli, M., Atıcı Ulusu H., Gündüz T. (2018). Pirinç paketleme işinde çalişanlarin çalişma koşullarinin ergonomik risk analizleri ile geliştirilmesi. Balıkesir Üniversitesi Fen Bilimleri Enstitüsü Dergisi, 20 (1), 38–54.
• Tekin, M., Arslandere, M., Etlioglu, M., Koyuncuoglu, O., Tekin, E. (2018). Application of value flow mapping to a big scale business. Engineering and Technology Management Summit, 300–311.
• Tokel, D., Dogan, İ., Hocaoglu-Ozyigit, A., Ozyigit, I.I. (2022). Cotton agriculture in Turkey and worldwide economic impacts of Turkish cotton. Journal of Natural Fibers, doi: 10.1080/15440478.2021.2002759.
• Uslu Divanoğlu S., Taş Ü., Pak E. (2021). Application of methodology of kaizen in assembly line in a production facility in the automotive sector. Journal of Polytechnic, 24 (4), 1533– 1541.
• Kee D., (2021). Comparison of OWAS, RULA and REBA for assessing potential work- related musculoskeletal disorders. International Journal of Industrial Ergonomics, 83, 103140.
• Seth, D., Gupta, V., (2005). Application of value stream mapping for lean operations and cycle time reduction: an Indian case study. Production Planning & Control, Vol. 16, No. 1, 44– 59.