Implementing lean principles in assembly lines to reduce waste and enhance productivity.

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dc.contributor.advisorMatkó, Andrea Emese
dc.contributor.authorDangwal, Shaurya
dc.contributor.departmentDE--Műszaki Kar
dc.date.accessioned2026-02-02T16:39:42Z
dc.date.available2026-02-02T16:39:42Z
dc.date.created2025-11-17
dc.description.abstractThis thesis was conducted in Bürkle, Debrecen with a sole aim to showcase how the lean tools were implemented in the shopfloor of the company. Bürkle is responsible for assembly of the machine and selling it to its buyers world-wide. Some of its machines include photovoltaic laminators, plastic card manufacturers, etc. As this was a plant with an ‘unique production’ concept’ it required better and individual planning to meet the quality requirements in every machine being customized according to the customers’ needs. There were many problems identified while initially setting up the company like lack of proper documentation, many safety hazards, lack of skills, knowledge and experience of the workers. Various quality defects which were going unnoticed and all necessary machines and tools were not present but the plant had already started its operation. There were times when the workers would sit idle for hours waiting just because their machine stopped working. W Sometimes the electrical department had to wait for the mechanical department to finish working or sometimes there power outages which led to many processes coming to a complete standstill as the generators were not strong enough to run the whole company There were power cables lying around the floor and sometimes with their copper part outside. The incoming goods had also a problem as it did not have an organized section for it. The goods were unloaded in a different part of the company instead of the warehouse because some of the doors were not of the size of the parts and because of this they had to be moved to the other side of the factory. These factors played a huge role in the overall image of the company. To solve this various measures were taken such as implementing various lean tools such as 5S, Kaizen, 8 wastes etc. There was implementation of ISO 9001 standard which led to continuous quality checks on the various departments as part of the ISO standard implemented and was taken quite seriously. All of these measures led to a greater identification of already existing problems and helped to synchronize the assembly process with various departments of the shopfloor such as mechanical, electrical, quality check. There was the introduction of the ERP system which played a major role in modernizing the shopfloor. Every information was now a few touches away in a digitally stored database. Various training sessions were conducted for the workers which helped raise accountability for their work. This made everything start to work in a streamline motion and helped all the departments to get the necessary information and simultaneously reach their goals on time. All these steps led to a decrease of wastage during the assembly process and increased the efficiency of all the processes to its maximum. Various KPIs and analyses also helped in understanding and reaching the necessary goals of the company.
dc.description.courseMechanical Engineeringen
dc.description.degreeBSc/BA
dc.format.extent37
dc.identifier.urihttps://hdl.handle.net/2437/403941
dc.language.isoen
dc.rights.infoHozzáférhető a 2022 decemberi felsőoktatási törvénymódosítás értelmében.
dc.subjectImplementation of Lean Tools
dc.subjectAnalysis
dc.subjectReducing waste
dc.subjectEnhancing efficiency
dc.subject.dspaceEngineering Sciences::Engineering
dc.titleImplementing lean principles in assembly lines to reduce waste and enhance productivity.
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