Improving Production Operations through Lean Management: A Case Study in the Refrigeration Sector

This thesis focuses on the application of Lean Manufacturing tools and techniques to enhance the operational efficiency of an assembly line within a manufacturing setting in the refrigeration sector. The study systematically implements Value Stream Mapping (VSM), Pareto Analysis and 5S methodologies to identify inefficiencies and streamline processes. Additionally, discrete event simulation is employed to model and optimize the system, enabling data-driven decision-making for continuous improvement. The research aims to reduce production lead time, processing time, and production wastes, while simultaneously improving warehouse space utilization. Through VSM, the current state of operations is mapped, highlighting critical areas of waste and bottlenecks. Pareto Analysis is utilized to prioritize key problem areas, focusing efforts on high-impact issues. The 5S framework is then applied to enhance workplace organization, standardization, and cleanliness, contributing to overall process efficiency. The implementation of simulation further supports the identification of optimal scenarios for balancing the assembly line and managing resources effectively. As a result of these combined efforts, significant improvements are achieved in lead time reduction, cost minimization, and optimized floor space utilization. The findings demonstrate the tangible benefits of integrating Lean Manufacturing tools with simulation for operational enhancement, offering practical insights and recommendations for future improvements in similar manufacturing environments.