Implementation of Lean Manufacturing System in Cement Plant by using an AI Approach

Organizations today face intense domestic and global competition driven by liberalization and rapid technological advancements. To sustain a competitive edge, managers adopt proven management philosophies such as Just-In-Time (JIT), Total Quality Management (TQM), Total Productive Maintenance (TPM), Six Sigma, and Lean Manufacturing Systems (LMS). However, selecting between people-oriented systems like LMS and technology-driven systems such as Flexible Manufacturing Systems (FMS) or Computer-Integrated Manufacturing Systems (CIMS) remains a challenge, as such initiatives demand significant investments and long-term commitment. This study focuses on implementing Lean Manufacturing Techniques such as TPM, 5S, and Kaizen in the cement plant. The three major performance parameters, such as Overall Equipment Effectiveness (OEE), Average Setup Time (ST), and Defect Rate Percentage (DP), have been evaluated. The AI tool, such as Artificial Neural Networks (ANN) and Genetic Algorithms(GA), has been applied for process optimization. It has been found that there is an improvement of 41%, 70% and 90% in OEE, ST, and DP, respectively, after applying LMTs in the cement plant.