Application Of Lean Manufacturing Research Articles

The effect of lean manufacturing and physical work environment on labor productivity in the apparel industry in Indonesia: case study

In general, this research aims to analyze and determine the effect of the application of lean manufacturing which is focused on eliminating waste and the influence of the physical work environment on labor productivity. This research used primary data through the distribution of questionnaires conducted to employees of Company X with a total of 230 respondents from sections in departments directly related to research variables. Data analysis methods using the Structural Equation Model (SEM) measured by the Partial Least Square (PLS) model, and data processing using SmartPLS 4.0 Software. Based on the results of calculations, data analysis shows that the application of principles related to lean manufacturing, which in this research is focused on the process of eliminating waste has a positive effect on the productivity of the workforce. The creation of a physical work environment that meets standards also positively affects the productivity of the workforce.

A Review of Literature on Lean Manufacturing Tools and Implementation Based on Case Studies

This research focuses on reviewing the Lean Manufacturing (LM) implementation which is widely applied in the manufacture company to overcome or reduce waste. The aim of this article is to find out more about the influence on the industry sector. This research was developed by collecting research from indexed databanks of Scopus, Science direct, ResearchGate, etc. This review study is significant to identify the application of lean manufacturing in dealing with waste through implementation into several case studies. A total of 24 articles were selected, taking into account criteria such as keywords, article titles and publications of international publishers, which were selected through a systematic process. This study found that the application of lean manufacturing is a method that brings many advantages that work by minimizing losses and waste, and the Value Stream Mapping method is more often used as part of several Lean Manufacturing techniques to identify and analyze the occurrence of waste while providing solutions that lead to improvement. process and cost reduction.

Implementation of Lean Manufacturing Methodology and Its Application: A Literature Review

This study aims to investigate and analyze several previous works of relevant literature on the Lean Manufacturing technique in international journals. The methodology used to review the previous studies was carried out through a survey based on descriptive, qualitative, and bibliographical surveys in International Journal with restriction to the period of publication from 2017 – 2022 published on databases and electronic journals in English with the scope to examine and analyze in-depth the extent to which literature used to discuss results in the selected papers of applying the Lean Manufacturing technique in several case studies. After conducting a survey, only thirty-three articles were found with the theme of the application of Lean Manufacturing and its technique in manufacturing companies. Twenty-one techniques/tools of Lean Manufacturing were found problem-solving for waste time elimination, reducing process cycle times, and implementing process improvement. It is concluded that the most used methodology in waste reduction is Value Stream Mapping.

Application of Lean Manufacturing to Minimize Waste in The Production Process of Tin Stabilizer

Lean Manufacturing concepts were being used by the manufacturing sector more and more in an effort to maximize resource usage, cut costs, and increase efficiency. The research dived into the underlying concepts of Lean Manufacturing and its various tools and strategies for identifying and removing waste, such as overproduction, defects, needless inventory, wasteful motion, transportation, overprocessing, and waiting periods. Lean manufacturing methods could be implemented in the continuous manufacturing environment to detect and reduce waste by using a process flow chart, value stream mapping tools, waste assessment model, value stream analysis tools, and the 5 why’s method. According to the findings of the study, the most prevalent waste in the manufacturing process was waste flaws, delays, and wasteful inventory. Process activity mapping (PAM), one of VALSAT’s extensive mapping technologies, was used to eliminate waste. The lead time was reduced by 12 days and 1 hour as a consequence of the improvement recommendations study. NVA activity was reduced from 75.3% to 59.5% based on the PAM study. Reduced lead time could result in a more efficient production process and lower production costs.

Implementation of Lean Manufacturing to Improve Production Efficiency: A Case Study of Electrical and Electronic Company in Malaysia

The manufacturing industry plays a crucial role in the economy development of a country includes Malaysia. Lean manufacturing is a production method that aims to minimize waste and optimize efficiency in the manufacturing process.By applying lean manufacturing,it enablesa company topursues continuous improvement and integration of labor with a clear focus on value adding activities and elimination of waste. However, this concept is still not widely being applied by all type of company or limited in certain aspects only. This study aims to implement lean concept into a medium sized electronic company in Malaysianamed as Company ABC, particularlyto improve the efficiency of the production line. Company ABC is expanding its production line, thus looking forward to implement 8 Waste and VSM to improve the Line Balancing Rate and improve the line productivityfrom 1500 units/ week to 3000 units / week.The clarifications lead to this study is to understand, how the Implementation of Lean Manufacturing can help to improve the production line efficiency, what are the factors that causes producibility issues during design development stage and what are the area of improvement of the manufacturing line of Model X that could be enhanced and applied in this particular project. The goal of this study is to assess the contributionof Lean six sigmain the companyto increase the process line productivity and maximize the efficiency of the production process. Amodelwas developedto simulate the efficiency improvement of the production line after application of Lean Manufacturing.

Identification and Minimization of Waste with the Application of Lean Manufacturing in the Cireng Production Process at PT Brecxelle Berkah Uniti

Based on the results of observations and the 7 waste questionnaires at PT Brecxelle Berkah Uniti production, it was found that the waste of defects occurs such as cireng are shapeless, destroyed, and do not pass through the metal detector machine. Waste of waiting occurs during the cooling process, when starting the engine, and waiting for the pressing process. Waste of transportation occurs due to circular and non-consecutive process flows. This research aims to minimize production time and increase production result by simulating the cireng production process of PT Brecxelle Berkah Uniti using the Lean Manufacturing and System Simulation method. Based on the simulation results with the proposed improvements, the results obtained from the simulation were that the total production lead time was reduced by 10,97 minutes from 40.45 minutes to 29,48 minutes. The NVA and NNVA time on FVSM also decreased by 10.81 minutes from the activity time on CVSM. Based on the simulation results, production results increased by 80% after the proposed improvements, from 4,671,945 pcs per month to 8.429.679 pcs per month.

WASTE REDUCTION AT PT. X WITH LEAN MANUFACTURING APPROACH

In 2020 PT. X produces approximately 220 thousand packaging, this causes the paper raw materials used to exceed the maximum limit or exceed the insheet determined by the company. So that there is a loss to the company, both in terms of material and time. There are 3 types of waste or damaged products that are most dominantly found using lean manufacturing methods. The three most dominant wastes are excess insheet, non-standard color and excess glue. The application of lean manufacturing is expected to reduce waste in 2020 and maximize the profits obtained. In implementing lean manufacturing, it is supported by using value stream mapping methods and process activity mapping which is expected to get factors that cause waste. Waste that occurred in 2020 averaged 7.82%, greater than the standard set by the company with an average of 5%.

A-109 Application of Lean Manufacturing in Electrophoresis Test Processing in Order to Reduce Lead Time

Abstract Background There has been an increase on the demand for Protein Electrophoresis and Hemoglobin Electrophoresis exams over the past few years. This growth drew attention and motivated the laboratory’s Production Planning and Control (PPC) team to carry out a process flow analysis of the electrophoresis samples coming from the external units, which are responsible for approximately 60% of the total samples analyzed of these two exams. The study aimed to minimize waste throughout the process, optimize the use of resources, standardize continuous flows of activities, and reduce the Turnaround Time (TAT) of the samples in question, disseminating Lean culture and increasing the satisfaction of internal and external customers. Methods In order to reduce the TAT of electrophoresis exams from external units, the PPC team carried out on-site visits and revised the entire flow of processes related to these exams and others that could indirectly influence it, from collection and transport until the analyst’s signature and release of the result to the patient, mapping the entire flow covered by the samples and identifying possible important bottlenecks inherent to the activities, aiming at possible opportunities for improvement, through interviews, brainstorming, flowcharts and Design Thinking. Data such as the volume of monthly tests, percentage of external samples, TAT at the regional units, TAT at the Immunochemistry sector and total TAT were extracted from the laboratory’s automated data system and analyzed by the PPC team. With this, it was possible, through the Pareto analysis, to prioritize the obstacles to be overcome and focus on the main identified bottleneck, the amount of time for signing and releasing the reports, in addition to focusing on the random flow between the receiving and triage area and the processing technical area. Results Upon discovering that the greatest impact on processing time was located in the post-analytical phase of signing and releasing of the reports we suggested the capacitation of three extra analysts for the execution of the mapped action, the retraining of the technicians of the sectors responsible for the distribution of samples and supply of the machines and the standardization of a continuous flow between the areas, strengthening the Lean philosophy and the FIFO dynamics (First in—First out). Thus, we obtained a considerable decrease in the TAT of protein and hemoglobin electrophoresis, in which the total TAT of the operation was reduced by approximately 34% and the TAT referring to the time inside the Center of Technical Operations (CTO) by approximately 40%. Conclusion With the implementation of the above mentioned processes and the use of the Lean philosophy, the laboratory was able to considerably optimize the TAT of the Hemoglobin and Protein Electrophoresis exams, in addition to training employees to release results and enhance the standardization of receipt processes and distribution of these samples, with this, it was possible to optimize resources, increase the productivity of the sector, reduce the time of patient care and consequently maximize added value to the service.

Application of Lean Manufacturing to Minimize Waste in the Lajiem Coffee Business Production Process

Background - This study aims to implement the Lean Manufacturing method in the production sector in order to minimize the existance of waste in production proses of Lajiem Coffee. Design/methodology/approach - This type of research is qualitative research. By using the Lean Manufacturing method, the waste in the production sector of Coffee can be identified. The analysis used in this research is interactive models. Research implication - The results of waste identification using Timwood waste in the production sector found are Defect and Motion. Next, look for the root cause using 5-Why's in Root Cause Analysis (RCA), then assessed through Risk Analysis and mapped in a risk assessment matrix to find out the root causes of extreme risk. It is known that the extreme risks in the production sector are defects and motion. The next extreme risk is given improvement suggestions in order to minimize and reduce waste that has occurred in the production.

Lean construction methodology in the optimization of the results of a building project

Within lean manufacturing applications, its contextualization in construction processes is found as lean construction. This approach aims to reduce non-value-adding activities by optimizing processes to maximize efficiency. Thus, the objective of this research was to propose a procedure for adopting the lean construction methodology to contribute to the optimization of building projects. A mixed-method study was conducted with a cross-sectional, descriptive focus based on the case study: construction of a recreational theme park for terminally ill children. A procedure structured in six steps was designed, allowing the adoption of the lean philosophy in project management and the design of a tool to assess the project team's competencies in integrated management systems. The results enabled the definition, design, and delivery of project assets with the highest possible value generation, where lean methodology principles were applied. Likewise, the integrated project systems, stemming from incorporating lean methodology principles, optimized project productivity in building construction.

Application of Lean Manufacturing in Aluminum Cable Ladder Manufacturing Companies: Case Study at PT. Indra Saputra Triassic

After the Covid-19 pandemic, the manufacturing industry was faced with the challenge of continuing to create the highest quality products at the lowest possible cost and in the shortest possible time. PT also experiences this. Trias Indra Saputra is a manufacturer of Aluminum Cable Ladder located in Kabupaten Tangerang, Indonesia. Lean manufacturing is one method that can be used to identify and reduce waste in the production process. The existence of waste in the production process can lead to increased cost and processing time for a product. Value Stream Mapping (VSM), as an approach in Lean Manufacturing, can be used to find problems in the flow of products and information. Identification of waste begins with describing the current state of VSM and then analyzing the waste into 7 categories. After obtaining the waste category, continue conducting a Root Cause Analysis before designing and taking action to improve the process. By implementing Lean manufacturing PT. Trias Indra Saputra can reduce production time by 52%, Man Power by 70%, and production cost by 34% with the same quality even better than before.

Lean Accounting, Fat Problem? A Critical Analysis of Lean Accounting’s Value

Lean accounting is an accounting system that is designed specifically to facilitate the application of lean manufacturing. It is considered a new tool among the various accounting methods available to management. As a managerial accounting method, the purpose of lean accounting should be to provide valuable, insightful information to management for decision-making. However, lean accounting sometimes fails to serve this ultimate purpose as a managerial accounting alternative. We conduct a case study of Toyota to examine lean accounting’s value. The analysis shows that lean accounting tends to be short-term focused, which may jeopardize a company’s long-term growth prospective. Lean accounting is also incapable of providing accurate product cost information, and therefore is unable to support a strategic decision-making process. Traditional standard costing and activity-based costing may be superior to lean accounting for long-term planning and decision-making. The potential exists for a dual system with lean accounting for tactical short-term information and either standard costing or activity-based costing for strategic long-term information.

The Design of Android-Based Interactive Lean Manufacturing Application to Increase Students' Work Skill in Vocational High School: The Development and Validity

Vocational education graduates should have expertise competencies according to their fields so that it is easy to fill the job market, but this condition is not in line with expectations. BPS data as of February 2020 still shows the open unemployment rate, which is dominated by SMK graduates, at 8.49%, meaning that it is the highest-ranking contributor to open unemployment. One indication of this high percentage is the lack of work skills for vocational school graduates in the world of work. This lack of work competence is indicated because the learning process is not integrated with the real world of work. Therefore, improvement steps are sought through a learning process that integrates school learning with the real world of work by developing media that support learning activities with the real world of work. Therefore, the purpose of this research is to design an Android-based interactive lean manufacturing application to improve the work skills of vocational students. This study uses the 4D development method (four-Ds) for the development of android-based interactive lean manufacturing applications and uses a survey method for validity and this AR application will be validated by 3 experts. The results of this study indicate that the validation test of android-based interactive lean manufacturing applications is included in the valid category. So, it can be concluded that the Android-based interactive lean manufacturing application technology has been valid to be used in the learning process.

Обзор практик применения бережливого производства в клинических лабораториях

The main role of clinical laboratory diagnostics is to obtain reliable, reproducible and timely results that help to make the right clinical decisions. As the literature review shows, there are a number of common problems for many clinical laboratories, such as: long turnaround times, high laboratory costs for consumables, insufficient level of satisfaction with quality of services received by patients and high number of complaints. The use of lean manufacturing can be one way of solving these problems. Purpose of the study is to summarize and analyze the literature regarding the application of lean manufacturing in clinical laboratories. Materials and methods. A literature review was performed using the following abstract databases: Web of Science, Scopus, PubMed, ScienceDirect, Mendeley, and NCBI. The depth of the search according to the time parameter had no limitations. The following keywords were used as search markers: “lean management”, “lean thinking”, “lean six sigma”, “lean tools”, “healthcare”, “health services”, “clinical laboratory”. More than 100 publications were analyzed, from which 28 most representative studies were selected. Results. The implementation of lean production methods provides a reduction in turnaround time, costs and errors in the clinical laboratory, reduces the contamination of biological material at the preanalytical stage and reduces waiting time for services and, as a consequence, reduces the number of patient complaints. Conclusion. The above results indicate that lean production methods can be used in laboratories to solve frequently occurring problems and demonstrate the effectiveness of their application in clinical laboratories.

Research on optimization and simulation of sand casting production line based on VSM

Purpose This paper aims to provide feasible countermeasures for the application of lean manufacturing in automatic sand casting workshops to optimize production line balance. Design/methodology/approach A production line balance optimization model for sand casting workshops is proposed. The value stream mapping (VSM) approach is applied to diagnose the problems in the production process. An optimization scheme is established based on eliminate, combine, rearrange, simplify and increase theory and Kanban management method. Further, simulation is done to compare current VSM and future VSM. Findings After implementing the proposed model, findings indicated that the idle time of equipment was effectively reduced, the line of balance of the production line was increased by 44.7%, the production lead time was shortened by 60.3% and the production capacity was increased by 50.0%. Research limitations/implications Application of the optimization model in this study is limited to sand casting workshops that have realized automatic or semi-automatic production. Originality/value This paper provides an optimization model for the implementation of lean manufacturing in sand casting workshops and provides a reference case that reflects the actual application of lean manufacturing tools in a real situation.

Application of lean manufacturing using value stream mapping (VSM) in precast component manufacturing: A case study

Prefabrication of structural concrete elements and assembly at site offers advantages such as reduction in construction time, improved quality and reduction of material wastage. These advantages depend on standardization and good organization of work at the precast component manufacturing unit. The need in a precast factory is to ensure a smooth and delay-less manufacturing process so that wastes can be eliminated and better productivity can be achieved. The aim of this research paper is to apply lean principles and lean thinking using value stream mapping to reduce the processing time and increase the production in a precast component manufacturing unit. A precast component manufacturing unit in Chennai was chosen for the case study. The precast plant was visited to understand the entire manufacturing process. Value stream Map (VSM) of the manufacturing process was created using Lucidchart software. The wastes were identified based on seven wastes of lean. Changes were proposed to eliminate the waste which included change in layout of the manufacturing unit and handling devices. Future state map was created for the improved manufacturing process. Comparison of cycle time and lead time was made for before and after the proposed changes. The lead time decreased from 1102 to 739 min and the production increased from 33 units to 40 units per day. Also, it is found that the efficiency and effectiveness improved by 49% and 21.2% respectively. The study demonstrates that it is possible to achieve improvement in production of precast component manufacturing unit using lean principles. Improvements in the reduction of lead time, reduction of waste and increase in production are achieved with simple techniques.

Design of a comprehensive methodology for the lean manufacturing implementation in the colombian context

Abstract:
 Introduction: This article is the product of the research "design of a comprehensive methodology for the implementation of lean manufacturing in the Colombian context", carried out during the years 2019, 2020 and 2021 in Bogotá, Cundinamarca.
 Problem: Existing Lean Manufacturing implementation methodologies do not take into account the organizational aspects of the culture of the country in which it is being developed, thus making its full implementation difficult.
 Objective: Propose a comprehensive implementation methodology that allows increasing the successful application of Lean Manufacturing in the Colombian industry.
 Methodology: This article presents the review and analysis of the existing implementation methodologies and the results of the analysis of problems in implementation processes in the Colombian industry, as well as the comprehensive implementation methodology designed.
 Results: To achieve the successful implementation of lean manufacturing in the Colombian context, an adequate follow-up of the implementation process is required, the commitment of the company's senior managers, the definition of appropriate leaders for the implementation process and the adequate training of personnel.
 Conclusion: This project seeks to propose a flexible methodology that adjusts to organizational conditions.
 Originality: This research integrates key success factors associated with the Colombian context in the implementation methodology.
 Limitations: The sample size of the diagnosis of the degree of implementation of Lean Manufacturing in the Colombian industry from which the key success factors to be included in the methodology are taken.

أثر التصنيع الرشيق في أنشطة الفرص التسويقية- دراسة استطلاعية في الشركة العامة لصناعة الأدوية في سامراء

The success of any company did not come suddenly, but through the application of lean manufacturing tools and continuous monitoring of the needs and desires of customers in the market and seizing opportunities and exploiting them in those markets. The research problem is determined in how to apply lean manufacturing and exploit marketing opportunities in the research sample company .The research aims to identify the reality of lean manufacturing in the research sample company and its role in achieving marketing opportunity activities and eliminating waste to reduce costs, reduce time and increase productivity. The research community represented the managers of the higher administration, and an intended sample of (31) managers was chosen to properly represent the community. The General Company for Drug Industry in Samarra was chosen as a site to conduct the research. The search used statistical software (Spss Var. 19). The research concluded with a set of conclusions such as: The application of lean manufacturing in the company The research sample contributes to exploiting the available opportunities by reducing waste and reducing time and cost in a manner that suits the company’s objectives. In addition to presenting a set of recommendations such as: The company's management must adopt the proper application of the philosophy of lean manufacturing and its role in harvesting marketing opportunities and work to ensure the success of this application because of its significant impact in reducing costs and achieving a competitive advantage for the company.

Importance of the Application of Lean Manufacturing and Sustainable Manufacturing and Its Impact on Productivity and Quality in the Electronics Industry of Mexicali

An evaluation of use of lean and sustainable manufacturing tools was made, correlating them with the productivity and quality indices in an industry of the electronic sector located in the city of Mexicali. In this evaluated company, it was observed that some improper manufacturing methods was used and for this reason, generated a large amount of waste from electronic devices and electronic boards. This caused the productivity and quality indices to decrease, originating the need for extra time and with it unnecessary costs that devalued the prices of manufactured products, due to the competitiveness in the electronic industry sector evaluated. With the application of tools of lean manufacturing and sustainable manufacturing, the productivity and quality levels were increased and both overtime and unnecessary costs were reduced, achieving competitive prices in the evaluated industry. The installation method of electronic components with polarity in electronic boards was evaluated, due to the fact that a great diversity of products emerged from the automatic insertion area with defects, indicating reversed polarity, which should be solved, otherwise, short circuits could be generated or lack of electrical conductivity, in the manufactured products in their final process. This caused the manufactured products to not work properly, causing the presence of defective products and with it low levels of productivity and quality and economic losses. and It was detected that this occurred due to the lack of training of the operative personnel and the neglect of the operative workers of the automatic insertion area. In order to control this situation, as a methodological part, schematic models were developed to support the operational personnel in their activities in the automatic insertion area. This proposal with the schematic models developed for use in the electronics industry, where the research was made. The study was developed from 2018 to 2019.

Application of lean manufacturing to improve procurement lead time in the case of the steel industry

The steel industry is classified as a strategic industry that supports many industries, due to continuous national development. The steel industry must improve the quality of its production processes in order to increase its competiveness. One factor that supports the stability of the production process is the procurement process. Delays in the procurement process can disrupt the smooth production process. The purpose of this research is to minimize waste in the steel procurement process by using the value stream mapping method. This research begins by making current state mapping of the actual procurement process, then analyzed the activity categories including value added activity and non-value added activity. In the beginning, the total time value added activity is 7488 minutes and total time non value added activity is 12240 minutes. An improvement was made in terms of the negotiation process, document review, and waiting for an offer, the result of the total value added activity is 7488 minutes and non-value added activity is 2160 minutes, so the procurement process initially 41 days became 21 days.