IMPROVING PRODUCTION EFFICIENCY AND QUALITY IN AN ALUMINUM PROCESSING COMPANY THROUGH LEAN PRACTICES

Abstract

This paper analyzes the application of Lean methodologies to improve the efficiency and quality of production in the aluminum foundry MTC "Nissal." The enterprise specializes in the manufacturing, refining, and shaping of aluminum and its alloys. It operates via two primary divisions: profile extrusion and aluminum rod manufacture. The main findings indicate a 14% decrease in production time mostly caused by equipment failures, and a significant rate of faults, with 71% of the defects being attributable to operator irresponsibility.By implementing Lean methods such as the 5S methodology and Statistical Process Control (SPC), the analyses showed areas that may be improved. The 5S audit revealed workplace organization and cleanliness, with an average score of 1.73 out of 5. The 5S shine phase had the lowest score of 1.38. The SPCanalysis conducted on the manufacture of billets in EN AW 2011 alloy revealed a process capability index (Cp) of 1.154 and a process capability performance index (Cpk) of 1.015. These values indicate that the process is incapable and exhibits some inconsistency.By implementing Lean techniques, the enterprise aims to decrease downtime, minimize defects, and improve overall production efficiency and quality. This will help establish MTC "Nissal" as a strong competitor in the aluminum market.