Implementation of Lean Tools to Improve Mass Production of a Laser Cladding Process

Laser cladding is one of the state of the art technologies in metal coating that is found advantageous over conventional welding and repairing technologies due to its innovative microstructural, metallurgical, and strength characteristics. Although various studies have been focused on implementing lean tools in different fields, there is a lack of such implementation on the cladding process. This study aims to use these tools in a laser cladding process and is intended to address the areas requiring improvement of the deadtime, with a prime focus on minimizing the waste and increasing overall equipment effectiveness. After analyzing the entire flow of the process through Value Stream Mapping, the laser cladding machine was recognized to be the bottleneck. As such, efforts were focused on minimizing the non-value-added time attached to this process. Further, the study identified the major root causes, including limited process standardization, absence of maintenance schedules, unnecessary motion, inefficient machine design, and health and safety risks. To address these major causes, a course of action was developed using Lean tools such as Ishikawa diagram, Standard Operating Procedure, Cleaning, Lubrication, Inspection, Tightening sheets, and Single-Minute Exchange of Die. These recommendations discuss improvements involving the reduction in the cycle time and increased productivity while also reducing safety risks due to high exposure to powder and temperature. It was observed that the deadtime was decreased by 41.6%, whereas the productivity increased by 20.9% after implementing the proposed recommendations on the shop floor. Furthermore, the Single-Minute Exchange of Die methodology is drafted to develop an efficient machine design that can increase productivity to about 66.6% after successful implementation.