An integrated framework for lean manufacturing in relation with blue ocean manufacturing - A case study

Abstract

Lean Manufacturing (LM) has traditionally helped industries in removing the non-value-added processes to achieve operational excellence. Similarly, the blue ocean strategy helps organizations in creating an uncontested market space where the competition is irrelevant. The authors posit that the integration of two approaches helps in achieving holistic manufacturing excellence, and there is a paucity of approaches that integrate the two paradigms. In order to fill this research gap, the authors have developed an integrated framework that combines the concepts of lean manufacturing and blue ocean manufacturing (BOM), via a structured survey. Using the lean tool of value stream mapping and four-action framework of BOM, the framework was duly implemented on the selected case study and reductions in lead-time and value-added time were recorded to be 26% and 39% respectively. In addition to that, more than 50% reduction in the environmentally detrimental GHG emissions was recorded through the implementation of the integrated framework. The novelty of the research work lies in the amalgamation of lean manufacturing and Blue Ocean manufacturing, concomitant to which economic and environmental sustainability can be achieved. The framework provides clarity to practitioners and academicians regarding the implementation of two approaches (LM and BOM) in a harmonious manner to attain reduction in non-value added activities and delivery times which attains market leadership through high-quality product manufacturing with lower production time and costs. This economic lever is capable of delivering economic sustainability and implicates improved environmental performance through reduced energy consumption. In future, research work can be carried out using the innovative concepts of Industry 4.0 with lean and sustainable manufacturing.