Application Of Fmea Tool To Prevent Errors In The Production Process Of Safety Helmets - A Case Of X Helmet Company

Abstract

This thesis investigates the efficacy of continuous improvement strategies in implementing lean tools to enhance product output within the automotive industry. The core research problem revolves around understanding how a systematic approach to lean implementation can boost production efficiency. Employing a single case study design, the research focuses on a specific automotive manufacturing facility. Data collection methodologies included process mapping, observation, and employee interviews to assess current production processes and pinpoint areas for improvement. Lean tools such as Value Stream Mapping (VSM) and Non-Value Added Reduction were implemented in a phased approach, with continuous data collection to measure their impact on production output. The analysis revealed a marked improvement in product output following the implementation of lean tools. Bottlenecks were identified and addressed through process redesign, leading to a smoother workflow and reduced waste. The findings indicate that continuous improvement in lean implementation can significantly enhance production efficiency by streamlining processes and fostering a culture of problem-solving and employee engagement within the automotive industry. This study contributes to a deeper understanding of how lean tools can be effectively utilized for continuous improvement in a real-world automotive setting. The implications extend to other manufacturing environments aiming to optimize production processes and improve overall performance. Future research could explore the long-term sustainability of lean practices and their impact on factors such as employee satisfaction, quality control, and cost reduction.