Model for eliminating motion waste in a manufacturing company using KPIs

Abstract

Purpose: The aim of this article was to develop and validate a model for identifying and eliminating motion waste in a selected production process using Lean Manufacturing principles. The paper also proposes a set of key performance indicators (KPIs) to support the measurement, monitoring, and continuous improvement of operational efficiency in a manufacturing environment. Design/methodology/approach: The research objectives were achieved by analysing work organisation at two production workstations using a spaghetti diagram and a set of KPIs. The approach was based on the principles of Lean Manufacturing, focussing on identifying and eliminating motion waste. Findings: A high level of motion waste was identified at both workstations. A lack of smooth workflow and excessive operator movement was observed. The proposed improvements will significantly reduce walking distances and improve work organisation. Research limitations/implications: A limitation of the study is that it is restricted to two workstations within a single company, which may affect the generalisability of the results. Furthermore, the analysis focused primarily on motion waste, overlooking other forms of muda. Further research will aim to extend the analysis to other types of muda, other types of production processes, and workstations, and to conduct an in-depth analysis of the impact of the implemented improvements on work efficiency and ergonomics. Practical implications: The results indicate that efficiency can be improved by reorganising the workstations. The use of KPIs plays a significant role, as they enable the ongoing measurement, monitoring, and evaluation of the effectiveness of the improvements being implemented. The proposed solutions, supported by the KPI system, can help reduce operating costs and increase production efficiency. Social implications: Optimising traffic flow has a positive impact on ergonomics in the workplace, which can improve staff comfort and safety. Originality/value: The value of this work lies in the integration of the spaghetti chart with KPIs in the analysis of waste in production. This study is aimed at Lean practitioners and production managers. Keywords: Lean Manufacturing, workflow analysis, operational efficiency, process optimisation, production engineering. Category of the paper: Research paper.