Implementing Lean Methodology in a Power Cable Factory - A Case Study of a Low Voltage Cable

Sep 13, 2026

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The paper analyzes the impact of implementing Lean methodology in a low voltage cable factory to improve production and time performance. Planned maintenance, autonomous maintenance, focused improvement, and OEE with daily performance reviews are applied to characterize practical effects on the current manufacturing process. Results show managers can identify and eliminate manufacturing waste, strengthening process effectiveness and enabling more efficient resource allocation. Lean adoption also reduces changeover time, cutting raw material delivery time, including an example of a 50% reduction from 180 to 90 minutes, and offers implementation advantages and recommendations.

LanguageEnglish

CategoryPresentations

FormatPDF

Pages15

Reading Time5 min

AccessFree to download

Introduction

Literature Review

Lean tools and maintenance approach

Practical implications and results

American Journal of Industrial and Business Management, 2019, 9, 2083-2097 [https://www.scirp.org/journal/ajibm](https://www.scirp.org/journal/ajibm) ISSN Online: 2164-5175 ISSN Print: 2164-5167 Implementing Lean Methodology in a Power Cable Factory: A Case Study of a Low Voltage Cable Mohammed Alamoudi, Rami H. Alamoudi Department of Industrial Engineering, King Abdulaziz University, Jeddah, Saudi Arabia How to cite this paper: Alamoudi, M. and Alamoudi, R.H. (2019) Implementing Lean Methodology in a Power Cable Factory: A Case Study of a Low Voltage Cable. American Journal of Industrial and Business Management, 9, 2083-2097. [https://doi.org/10.4236/ajibm.2019.912138](https://doi.org/10.4236/ajibm.2019.912138) Received: October 30, 2019 Accepted: December 3, 2019 Published: December 6, 2019 Copyright © 2019 by author(s) and Scientific Research Publishing Inc. This work is licensed under the Creative Commons Attribution International License (CC BY 4.0) . [http://creativecommons.org/licenses/by/4.0/](http://creativecommons.org/licenses/by/4.0/) Open Access Abstract The paper discusses the effects of implementing Lean methodology in a low voltage cable factory with the goal of enhancing production and time performance. Several different tools in the Lean methodology were used in this study, including planned maintenance, autonomous maintenance, focused improvement and OEE & daily performance review. It is important to understand the current manufacturing process practiced in power cable factories. The practical effects and results of these tools are characterized in this study to help enable companies to use lean thinking. Practical implications; results indicate that applying the technique, manager can easily determine and eliminate manufacturing waster from the process. By enhancing the effectiveness of the process, they will be able to maximize resource allocation. Manufacturing sector has to validate the methodology for fruitful execution of lean technique. The adoption of Lean methodology attributed to successful execution of projects in minimizing changeover time. This implies that raw material delivery time is reduced. For instance, the use of this methodology can lead to 50 percent reduction time that is from 180 min to 90 min. Other industries such as manufacturing industry can adopt this method to reduce the production and delivery time. Pilot examples of how to use lean methods are also described so that lean methods can be applied to other machines. Finally, the paper outlines the advantages of incorporating lean methodology into a company’s projects and makes recommendations based on observations. Keywords Lean Methodology, Autonomous Maintenance, Focused Improvement, TPM, Overall Equipment Effectiveness, Power Cable Factory, Low Voltage Cable DOI: 10.4236/ajibm.2019.912138 Dec. 6, 2019 2083 American Journal of Industrial and Business Management 1. Introduction Power cables are often used to transmit high voltages from one grid station to others. The consumption of cables has increased in recent years due to the installation of new power plants and grid stations across the country. Therefore, the production requirement has increased over the last few years. Power cable factories are working to achieve production requirements using advanced technology and effective manufacturing systems. The purpose of this study is to improve the current manufacturing processes of the low voltage power cables to overcome the constraints associated with the current manufacturing system. The application of low voltage cables is increasing in complexity due to technological advancements that require improvements to cable harnesses. Thus, low voltage cable productivity has become critical for the power cable companies. The cable production rate of a company has decreased over the prior six months due to poor performance in the cable manufacturing process. Lean methodology is applied in thi

FAQs

What Lean tools are applied in the low voltage cable factory case study?

The study uses planned maintenance, autonomous maintenance, focused improvement, and OEE with daily performance review to assess improvements in production and timing.

How does the paper evaluate performance changes after adopting Lean?

It uses planned maintenance and other Lean-based tools alongside indicators such as consumer loyalty and mishap records to measure changes in performance.

What time-related improvement does the paper report?

The adoption of Lean reduces changeover time and raw material delivery time, with an example showing a 50% reduction from 180 minutes to 90 minutes.

Sep 13, 2026

Upload by Jacob