Lean Manufacturing Methodology and its Role in Increasing Productivity and Reducing Costs at To-me Cosmetics Company رسالة ماجستير

Abstract

In today's competitive markets, with increased competition in the labor market, increased demand for industries, increased awareness of customer quality and the need for better efficiency, reduced cost, improved quality, reduced variance and increased productivity, companies have to became more keen on an aspect of continuous improvement. And its adoption as basic standards for organizational culture. Hence, companies tend to use Lean Management System to increase their productivity and improve their business processes with quality, efficiency and effectiveness through the effective application of Lean tools. This study examines the effect of applying the Lean manufacturing methodology on industrial companies in the cosmetics sector. Furthermore, this study explains how applying this methodology can help beauty product manufacturers make the most of their resources and organize the workplace to become more productive. The importance of this study stems from the need to improve the productivity of the liquid production line, take advantage of warehouse space and establish a maintenance system in To-me Cosmetics in Ramallah by eliminating waste and reducing variance in order to survive in the rapidly developing world. Lean Manufacturing Methodology was implemented using a combination of tools such as VSM, 5S and TPM. The current performance in the measurement phase was measured using a VSM, Flowchart, Eight Wastes. The Root Causes of the problems were identified using a cause-and-effect diagram and interrelationships paragraph. The planning and Data were collected through interviews with the company staff and the live observation of V production process data like cycle time and delay time, which was essential to identifying process efficiency and potential improvement opportunities. Productivity of the fluid line production process is improved by using the first three stages of the 5S concept, the flow chart, and the value flow planning. The results achieved were maintained using the last two phases of the 5S concept, the flow chart, business models, and checklists. At the end of the optimization efforts, fluid production line productivity and planning were improved reducing the lead time for kitchen cabinet doors production from 2707 minutes to 1096 minutes with improvements in warehouse space utilization resulting in a more streamlined work environment, reducing the number of accidents by 45%. Moreover, inventory management is improved by controlling the procurement and storage of raw materials. The use of TPM also contributed to establishing a maintenance system, reducing wasted time, and controlling maintenance parts and maintenance operations on machines. This study contributes to the definition of the application of lean management in small and medium-sized enterprises in the Palestinian industry, and confirms the importance of this methodology in improving quality by eliminating waste and reducing variance, which plays a major role in the survival of the Palestinian economy, which faces many challenges.