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Title:	A framework for RFID technology combined lean implementation in automotive parts manufacturing industry
Authors:	Muhammad Zeeshan Rafique (P77748)
Supervisor:	Mohd Nizam Ab Rahman, Assoc. Prof. Dr.
Keywords:	Waste Barrier Framework Universiti Kebangsaan Malaysia -- Dissertations
Issue Date:	9-May-2017
Description:	Lean manufacturing is a leading paradigm for fast and proficient manufacturing but its proper implementation is a foremost task due to certain wastes and barriers affecting in operational, managerial and financial regime. In order to tackle these issues, a trend has been observed regarding the utilisation of technologies like Radio Frequency Identification (RFID) because of its properties like operational visibility and real time data information. But sometimes, this philosophical and technological combination lacks to provide required output because of unavailability of lean implementation framework combined with technology deployment study. Therefore, the aim of this study is to propose a framework for lean implementation which must have the ability to first confirm what type of wastes and barriers involved in the current operations and then to utilise technology by using proper technology deployment tools like Technology-Organisation-Environment (TOE) framework. In order to fulfil this aim, a longitudinal case study has been conducted and a structured interview based survey has been done for detection of frequent wastes (over transportation and over waiting), frequent barriers affecting lean (lack of information visibility and leadership) and main aspects of TOE framework (like requirement of information visibility and management commitment) through Rasch model which confirmed that current system require RFID technology with the management commitment and also evidenced the feasibility of TOE framework for technology selection. After this confirmation, the next task was the designing of conceptual framework that has been done through previous literature consisting of 21 steps with four implementation phases in which the interrelation between Value Stream Mapping (VSM) tool for lean implementation, TOE framework, wastes detection and barriers detection has been thoroughly constructed on a single platform. The framework development has been achieved through implementing this conceptual framework on selected case study. The implementation has been started through conceptual and preparation phase (Phase 1 and 2) through successful transferring of lean knowledge and selection of product family. In lean implementation phase (Phase 3), the current state map has been drawn which located the wastes and uncovered problems like longer lead cycle time and delivery delays due to lack of information visibility and bad layouts. A simulation model of future state map has been developed through RFID controlled operations and new layout, which ensured improvements by reducing overall lead cycle time, excessive operations, Work in process (WIP), Non-Value Added time (NVA), excessive labour and cost per set by 37.7%, 11.3%, 37.7%, 25.8%,17.6% and 23.3% respectively. In completion phase (phase 4), the future state map transformation has been started with the successful execution of RFID based pilot study on actual plant operations which confirmed improvements in shipping section and helped to convince top management. After successful implementation, a final framework has been drawn and validated on the other two products of different classes. The validation process has been successfully verified through simulations and group discussion. The major strength and contribution of this study is the originality in its structure to achieve technology combined lean which can be considered as the next generation of lean. It provides an innovative concept of combining results of TOE with VSM to attain profitable RFID combined lean deployments. The limitation of this framework is its application only in automotive parts manufacturing sector and in future this framework should also be tested in other manufacturing sectors.,Ph.D.
Pages:	275
Publisher:	UKM, Bangi
Appears in Collections:	Faculty of Engineering and Built Environment / Fakulti Kejuruteraan dan Alam Bina

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