Process improvement in an onshore wind turbine blade industrial unit

Abstract The wind energy sector continuously improves manufacturing processes to meet the growing demand for renewable energy. Recognizing the complexity and extended duration of the wind turbine blade production process, alongside the need to uphold high-quality standards, this work aims to increase the efficiency of the production process of wind turbine blades by improving its cycle time production. To attain this objective, bottlenecks and critical subprocesses were identified, lead time and process cycle time were reduced, and production throughput was increased by minimizing non-value-added activities. To achieve these objectives, researchers employed action research and implemented a set of lean manufacturing tools. After implementing the suggested tools and improvements, the company experienced positive impacts including cost and waste reduction, better workplace organization, enhanced safety and final product quality, and improved efficiency and productivity. This study is relevant to firms seeking to enhance operational efficiency and quality by implementing lean practices. Thus, advancements in materials, automation, quality control, and digital technologies are driving improvements in the production of wind turbine blades. This work examines an alternative method for enhancing the production process of wind turbine blades by employing various lean manufacturing tools. These tools are relatively easy to implement, do not necessitate significant investments, and align well with the realities faced by many companies.