Faculty of Engineering - Department of Industrial

Organizations are currently facing a challenge to respond rapidly to customer needs
changing. To compete in this continuously changing environment, companies must seek
out new methods allowing them to remain competitive and flexible by reducing their
expenses lead-time. Such strategic objective can be attained by applying continuous
improvement techniques. Organizations can achieve improvement in productivity,
quality, and expenses. Such improvement is gained by waste reduction.
The objectives of this project is to enhance the productivity and reduction of the
manufacturing costs of the aluminum painting line at Al-Arabia Company for
Manufacturing and Painting Aluminum sections by using the continuous improvement
cycles, As the company faces a lot of problems such as low productivity and too much
waste either powder or aluminum wires. One of the continuous improvement cycles is
the Lean-Six-sigma process and in such cycle the lean tools can be applied according to
the DMAIC process of six-sigma. Lean manufacturing contains many tools e.g. time
study, Single Minute Exchange of Die (SMED), break-even analysis, root cause analysis
and Pareto charts analysis. Using such analysis tools along with the DMAIC process
produces a sustainable performance improvement.
This project achieved an improvement in productivity by implementing the new
reciprocators which helped in speed up the overhead conveyer, decreasing in the
changeover color’s time by applying Single Minute Exchange of Die (SMED) as the
Changeover time decreased by 28 minutes, By contracting with new powder suppliers the
quality of the powder is now the same with much lower in cost and that helped in
decreasing the manufacturing costs and by using solid works program a Recommendation
for the hanging station was made and ready to be implemented with its analysis and by
this recommendation it is concluded that it will be able to make this station more standard
and less in cost in the future work.