Lean Approach Research Articles

Acoustic emission monitoring for industrial pressure vessels and infrastructure

Acoustic emission (AE) is a phenomenon that occurs in materials that are exposed to stress. Defects in the material, such as cracks can grow and release energy in the form of a mechanical wave that propagates through the material. With the help of piezoelectric sensors, the mechanical wave is converted into an electrical signal. The signals are recorded by the measuring system and are available for further processing. Acoustic emission as a method that records and processes the incoming signals in real time is therefore very suitable for 24/7 long-term structural health monitoring. With new approaches in data processing, acoustic emission can be moved from the classic periodic test approach to an online monitoring process. The in-service monitoring brings measuring challenges with it, like application on hot surfaces and inside explosion hazard areas. New developments in hardware and software provide tailor-made solutions for a variety of monitoring tasks. The use of artificial intelligence algorithms helps to improve the analysis of measurement data and guarantees safe operation of pressure equipment and infrastructure around-the-clock. Some examples of continuous monitoring are shown on pressure vessels from the industry sector and on infrastructure buildings e.g., steel bridges. Also, a new lean system approach in structural health monitoring with acoustic emission is presented.

Overviewing Challenges and Solutions in Lean Manufacturing Implementation for Domestic Enterprises

Companies keep focus on enhancing the quality, efficiency, and customer satisfaction of their products and services while at the same time increasing their profits. Lean Manufacturing emerges as a potent strategy to address these imperatives via identifying and eliminating losses. Hence, it leads to optimized production processes and enhances overall performance of enterprises. This study presents an overview and analysis of lean manufacturing principles, implementation strategies, challenges, and economic benefits for Ukrainian enterprises. The main hypostatize of the paper was to investigate whether the Lean manufacturing approach is associated with different scope of businesses and whether it brings efficient outcomes for all of them. Based on conducted structured literature review the study highlights the versatility of lean methodologies across various industries and administrative processes. Employing scientific methods like comparative analysis and theoretical generalization, the research offers insights into the outcomes of lean implementations, including cost savings, productivity enhancements, and improved product quality for business organizations. The main outcomes of study underscore the critical role of strong leadership commitment and organizational culture in driving successful lean transformations. Through overviewing case studies and practical insights, the article illustrates real-world applications of lean manufacturing principles from different industries, exemplified by organizations AeroStar, Nova Poshta and Boeing. The paper is theoretical. However, the study advocates the practical importance of adoption of lean principles to achieve operational excellence for companies regardless of their scope of operating activities. Also, it offers suggestions for future research to explore emerging technologies' impact and cross-cultural comparisons in lean manufacturing practices.

Reduction of Setup Times in a Metal Fabrication Company Using a Lean-Sigma Approach

Manufacturing companies face demand fluctuations and must deliver the required quantity of parts to their customers within the required time; however, companies face different challenges in fulfilling them. One is technological advances, which make it impossible for them to compete with other countries, such as China, due to financial issues. Therefore, manufacturing companies use continuous improvement methodologies to achieve better performance in their processes. Six Sigma and Lean Manufacturing are some of the best-known approaches. This article briefly presents the application of a lean sigma approach oriented to solving problems. This research proposes a methodology based on Lean Sigma that contrasts what different authors currently do: continuous improvement projects that take up to 12 months to produce results and do not solve a problem. This implementation is conducted in a process that manufactures metal parts and fails to deliver them on time to its customers. Using tools such as the Single Minute Exchange of Die (SMED) in a production line, on-time deliveries were increased from 89 % to 96 %; at the same time, the model change times were reduced by approximately 60 %, which is required for the implementation of this methodology for only four weeks, unlike the traditional six-sigma approach that can take up to 12 months to improve the process.

Analysis of Value Stream Mapping (VSM) in the Application of Lean Manufacturing to Minimize Waste at PT. Karya Indah Medika

Achievements to minimize waste can be done by adopting a Lean manufacturing approach. Lean manufacturing is a concept that can design production processes to be better, faster, and cheaper with minimal space, small inventory, small labor hours, and avoid waste. This research takes the case study of PT Karya Indah Medika which is a company engaged in manufacturing to produce medical devices, medical device service services, and medical device installation. In the company there is still waste, especially in unnecessary movements and product defects. This study aims to identify waste that occurs in the company and provide recommendations for improvements in order to minimize waste and obtain optimal production time. Value stream mapping is used to describe all processes in the company. The results showed that the initial production time of 17 hours 18 minutes could be reduced to 1 hour 55 minutes. Based on the Failure Mode and Effect Analysis (FMEA) it is known that the root cause of the problem in the highest waste is workers in a hurry so they are not thorough in working with a Risk Priority Number (RPN) score of 294, lack of materials needed for production, placement of tools that are not in accordance with production needs and a warehouse area that is less extensive by 216.

Enfoque metodológico para el aprovechamiento de mermas de transformación agrícola basado en manufactura esbelta: Caso de estudio en una finca cafetera en Colombia

Improvements in production systems that use the lean manufacturing approach known as “Lean” have the objective of eliminating or reducing waste or process inefficiencies (muda). This approach is increasingly adopted by different industrial sectors, including agriculture. Although Lean improvements are traditionally applied to existing processes from cultivation to distribution, opportunities to intervene in processing wastes (losses) are left aside. This article presents a methodological approach framed in five Lean principles, made up of six activities aimed at the design of new processes that make use of the losses generated by harvesting and agricultural transformation. The methodological approach is applied in a Colombian coffee farm where parchment coffee transformation processes are developed. A parallel losses composting process is designed that transforms defective, green, overripe beans, coffee pulp, mucilage and husk. The results show that by applying the methodological approach on the coffee farm, a level of losses transformation of 86% is achieved. Molting is also reduced for both the current parchment coffee production line and the composting line to 35% and 50% respectively. The main reductions are reprocessing and waiting times. Finally, a 30.3% reduction is obtained in the time of activities that do not add value, making both the current and proposed processes more efficient and with better delivery times.

Waste Analysis In Delivery Process Using The Lean Distribution Method

In the current era of globalization, the existence of goods delivery service companies supports almost every area of human life. In the process of delivering goods, PT. X always strives to provide fast and precise service. However, the problem faced by the company is the long lead time for delivery of goods. This study employs a lean distribution approach, applying Value Stream Mapping and identifying waste using the 8 waste framework. The research findings revealed waiting recapitulation of 20%, excess processing of 18%, overproduction of 17%, defects of 13%, non-utilized talent of 10%, inventory of 9%, transportation of 7%, and motion of 6%. With proposed improvements, the delivery process time can be reduced from 8243 minutes to 5929 minutes.

Use of Lean Management Methodology to Reduce the Rate of Unfinished Nursing Care in the Emergency Observation Room: A Quality Improvement Project.

The integration of lean management in optimizing nursing workflow necessitates the careful examination of several factors, including nurses' work efficiency, patient experience, and health outcomes. To evaluate the extent of unfinished nursing care and patient satisfaction, we have incorporated the lean management approach into our quality improvement efforts. This proactive measure aims to address potential adverse outcomes, such as subpar inpatient experiences, escalated occurrence of adverse events, and decreased job satisfaction among nursing staff. We utilized the lean management methodology of value stream mapping in a specific facility between February and August 2021, aiming to pinpoint the crucial areas for enhancing nurses' workflow. By employing fishbone diagrams, we thoroughly analyzed the underlying causes, and subsequently employed the Plan-Do-Study-Act model to execute interventions devised based on these identified causes. Interventions included: (1) specifying the time of doctors' conventional rounds; (2) changing unreasonable scheduling; (3) employing 5S management to manage nursing supplies; and (4) eliminating duplicate papers and electronic reports. After implementing these interventions, the rate of unfinished nursing reduced from 73.4% to 39.6%, and that of finished nursing care during the shift increased from 38.6% to 71.4%. Overtime was reduced from 37.2 ± 22.4 minutes to 14.1 ± 3.6 minutes. The total patient satisfaction score for the Patient Satisfaction Questionnaire short-form increased (P < .05). The lean management of quality improvement methodologies provides effective enhancement to the work efficiency of nurses.

Higher Education Institutions as Strategic Centers for Promoting Social Innovation in Gerontology: Insights from the Senior Innovation Lab Training Initiative.

Social innovation and gerontology develop a wide range of actions aimed at supporting and improving the needs of long-lived populations. Higher education institutions (HEIs) are drivers of change, and their potential to develop solutions through teaching students' social innovation skills should be considered in the field of longevity. This article reports the results obtained by the Senior Innovation Lab (SIL) training initiative. Challenge-based learning, design thinking, and lean startup approaches were implemented in training 26 participants with the final aim of developing innovative solutions to previously identified long-lived population needs. Final products were innovative ideas developed through collaboration between students, academic staff, and business employees, indicating the importance of adopting entrepreneurial approaches in academic teaching. The participants identified motivation and perseverance as the most relevant entrepreneurial skills and most of them also perceived that they possessed it. The participants also considered spotting opportunities (chance to add value) as the most desired skill throughout the whole experience. SIL's assessment showed that social innovation methodologies contributed to the development of learning strategies, enabling potential solutions for the ageing challenges.

Lean approach applied to the blood gas system in point-of-care testing (POCT): The IRCCS San Gerardo dei Tintori experience

ABSTRACT Costs of medical care have increased worldwide, which may be due to unnecessary operational inefficiency. Different approaches exist to enhance procedural processes, and the Lean concept is used to improve quality and performance by systematically eliminating waste. In this study, Lean methodology with the four-stage Deming cycle (Plan, Do, Check, and Act) was applied to the point-of-care testing (POCT) system of the IRCCS San Gerardo dei Tintori. Starting from the evaluation of the current strategies used in the clinical laboratory, our goal was to facilitate workflow standardization, increase the efficiency, appropriateness, and quality standards in the execution of blood gas analysis in POCT, and to plan improvements, staff satisfaction, and safety. Six qualitative key process indicators, such as workflow, work area management, visual checks, reagents and supplies inventory, sample traceability, and work standardization, were used to investigate problems and identify solutions. The adoption of cutting-edge technologies, the training of personnel on the best pre-analytical practices, the standardization of cleaning procedures, the distribution of easy check workflow charts, and standardized material request documents reduced manual operations from 70 to 40% and patient identification errors of 10x. This approach created a diffuse collaborative culture and improved standardization of processes and safety.

Improving efficiency in green tea production time using lean manufacturing approach with value stream mapping: A case study at PT Candi Loka [Perbaikan efisiensi waktu produksi teh hijau menggunakan pendekatan produksi ramping dengan value stream mapping: Studi kasus di PT Candi Loka

Green tea production activities at PT Candi Loka indicated a time-consuming, which caused process efficiency to be less than optimal. Process efficiency improvements must be made to increase company competitiveness and consumer satisfaction. This research aimed to analyze the efficiency of green tea production time at PT Candi Loka by identifying the processing time required in each production activity, including the time consumption and formulating recommendations for improvement using a lean manufacturing approach using the VSM (Value Stream Mapping) method. There were 30 activities in 6 processes consisting of receiving raw materials, withering, rolling, drying, and packaging. Identification of value streams using the PAM (Process Activity Mapping) tool produced 9 Value added (VA) activities, 19 Necessary but Non-Value Added (NNVA) activities, and 2 Non-Value Added (NVA) activities in the form of delays in the withering and drying processes. In the current state map analysis, the production lead time value was 315.286 seconds. Recommended improvements to eliminate delays in the withering process were to set up the rotary panner machine earlier and increase the number of supervisors, while to eliminate delays in the drying process were to implement a piece rate system. Increasing efficiency was also carried out by improving NNVA activities by adding weighbridge facilities and using a conveyor system. The future state map proposed by implementing recommended improvements resulted in an increase in production time efficiency to 222.356 seconds and an increase in the process cycle efficiency value from 58.95% to 84.85%.

Predictive Model Using Machine Leaning Approach for the Detection of Breast Cancer

Predictive Model Using Machine Leaning Approach for the Detection of Breast Cancer

A Deep Learning Approach for the Fast Generation of Synthetic Computed Tomography from Low-Dose Cone Beam Computed Tomography Images on a Linear Accelerator Equipped with Artificial Intelligence

Artificial Intelligence (AI) is revolutionising many aspects of radiotherapy (RT), opening scenarios that were unimaginable just a few years ago. The aim of this study is to propose a Deep Leaning (DL) approach able to quickly generate synthetic Computed Tomography (CT) images from low-dose Cone Beam CT (CBCT) acquired on a modern linear accelerator integrating AI. Methods: A total of 53 patients treated in the pelvic region were enrolled and split into training (30), validation (9), and testing (14). A Generative Adversarial Network (GAN) was trained for 200 epochs. The image accuracy was evaluated by calculating the mean and mean absolute error (ME and ME) between sCT and CT. RT treatment plans were calculated on CT and sCT images, and dose accuracy was evaluated considering Dose Volume Histogram (DVH) and gamma analysis. Results: A total of 4507 images were selected for training. The MAE and ME values in the test set were 36 ± 6 HU and 7 ± 6 HU, respectively. Mean gamma passing rates for 1%/1 mm, 2%/2 mm, and 3%/3 mm tolerance criteria were respectively 93.5 ± 3.4%, 98.0 ± 1.3%, and 99.2 ± 0.7%, with no difference between curative and palliative cases. All the DVH parameters analysed were within 1 Gy of the difference between sCT and CT. Conclusion: This study demonstrated that sCT generation using the DL approach is feasible on low-dose CBCT images. The proposed approach can represent a valid tool to speed up the online adaptive procedure and remove CT simulation from the RT workflow.

Improving Market Access with a Lean Approach to Quality

Improving Market Access with a Lean Approach to Quality

Using a lean management approach in acute ischemic stroke management: a systematic review.

Stroke is the second leading cause of death worldwide with an annual mortality rate of 6.55 million, which accounts for 11.6% of the total number of deaths. Early diagnosis is crucial for improving treatment outcomes. Lean management is an approach originating in the car manufacturing process derived from the Toyota Production System, which healthcare providers have recently adapted. The objective is to examine the use of lean practices in managing AIS in hospital settings. A systematic literature search was performed using MEDLINE and SCOPUS databases, including publications from 1st January 2000 to 20th September 2022. A total of 13 studies fulfilled the predefined inclusion criteria. The recombinant tissue plasminogen activator (rtPA) was used in 11 studies, in 2 studies in combination with mechanical thrombectomy (MT). MT alone was used in the other 2 studies. The value stream mapping was used in all included studies to analyze workflow in acute ischemic stroke (AIS) treatment. Outcome measures include mostly door-to-needle (DTN) time for rtPA treatment and door-to-puncture (DTP) time for mechanical thrombectomy. DTN time was assessed in nine studies and reached statistically significant results in five. DTP was examined in three studies; in two, statistically significant decreases in DTP were observed. Lean management can be a useful method for achieving key performance indicators in AIS, consistent with current guidelines. The results of this systematic literature review show that value stream mapping may improve the process of AIS treatment by reducing in-hospital delays. The field of research that focuses on implementing lean management tools in healthcare is increasing, with more publications appearing in recent years.

Analysis UX Design e-Commerce "Key Kaos" with Lean UX

This research explores the evaluation of User Experience (UX) design at the Key Kaos online store using the Lean UX approach. Key Kaos online store required user-centered design to increase customer satisfaction and drive engagement. This study integrates Lean UX principles to simplify the design process, encourage collaboration, and rapid iteration.The research methodology includes a combination of user feedback, usability testing, and iterative prototyping, which aligns with the Lean UX framework. Through this iterative process, this research aims to identify key weak points and areas of improvementin the existing UX design of the Key Kaos online store. These findings are expected to provide valuable insights in increasing user satisfaction, improving usability, and optimizing the overall user journey in the market.Additionally, this research explores the impact of Lean UX on cross-functional collaboration, aiming to identify how Lean UX facilitates communication and collaboration between designers, developers and other stakeholders. By assessing the effectiveness ofLean UX in the context of Key Kaos, this research contributes to a broader understanding of its application in the market environment.The expected outcomes of this research include actionable recommendations to improve the UX design of Key Kaos online stores, ultimately contributing to market success by creating a more user-friendly and efficient platform. Additionally, research insightsregarding the application of Lean UX principles can inform future efforts in marketplace UX design, offering a valuable reference for designers and researchers looking to optimize user experiences in online marketplaces.

Adoption of Lean Approach to Enhance Performance of Fast-Track Construction Projects

Adoption of Lean Approach to Enhance Performance of Fast-Track Construction Projects

WASTE MANAGEMENT USING LEAN-GREEN APPROACH: A CASE STUDY IN A FURNITURE COMPANY

Introduction: Wooden furniture is one of Indonesia's superior products, with a low-efficiency level. However, the wooden furniture industry is often associated with intense environmental degradation and high levels of waste. In anticipating waste, a green manufacturing model proposed is Lean-Green manufacturing. This current study aims to explore the implementation of the Lean-Green model in a furniture company's waste processing system and assess the effectiveness of Lean-Green implementation. Methods: The research methodology was qualitative with the Lean-Green scoring method implemented in the supply chain of Company S. Data were collected through interviews and field observations. Results: Company S had a low score, meaning that the interaction between the Lean and Green approaches in the waste processing of the supply chain was not optimal. The Lean-Green implementation in the wooden furniture industry was effective in evaluating waste processing in the supply chain. The research findings urge the initiatives to improve the understanding and implementation of the Lean-Green concept. Conclusion and suggestion: The evaluation of the Lean-Green implementation helps the company’s manager improve the supply chain with sustainable measures.

Grounded Ambitions: A Lean Approach for Assessing Beachability in Concept Design

Littoral operations have become an increasing interest for defense stakeholders over the last several decades. Many navies currently operate ship-to-shore assets that are designed to travel shorter distances exclusively in the littorals between a ship and the beach. New concepts are being designed to transit much longer distances from shore-to-shore in both blue water and littoral regions. This Concept of Employment (CONEMP) drives these ships to displacements that are orders of magnitude larger. Compared to smaller vessels where seakeeping and maneuverability performance in the surf-zone are a significant area of interest, larger vessels have a comparatively greater risk with respect to the ability of the ship to get far enough up a beach to safely deliver assets and then get off the beach. This research presents the foundation for a new simulation tool to analyze how far up the beach a ship will be able to get given loading condition, initial speed, beach condition, and hull shape. The focus of this research is to provide a low computational-cost method for analyzing the beachability of a ship that still considers the dominating physical phenomena of grounding at early stages of design. The tool will need much faster turnaround times than high-fidelity Reynolds-Averaged Navier-Stokes (RANS) or Finite Element Analysis (FEA) simulations to support the rapid and evolving environment of concept design timelines.

Implementation Lean Teaching System forMathematics

Mathematic Teaching systems facing many challenges and factors that affect negatively its performance. As lean management approach succeeded in industrial sector, lean methodologies may be helpful in managing math teaching system efficiently and effectively, where improving quality of math teaching services may be achieved through the implementation of lean principles. Therefore teaching systems that are represented by schools, universities, and colleges are a suitable field to apply lean management approach. This study trying to investigate the implementation of some lean principles in managing math teaching systems with high performance. Also, this paper aims to implement a lean mathematical teaching system for high institute students of energy in Kuwait, it is expected that applying lean principles in the education system of math courses will improve the teaching and learning operations, increase the communication between all education system stockholders, improve skills of workers, and decreasing downtime or losses. Many hypotheses are presented and tested here using SPSS program. It was found that the math education system may be become lean-based if it has a multi-functional and flexible staff, continuous development and training for staff, and if there are a student training and qualifying activities, good management system, and continuous curriculum development.

Process improvement analysis in toll corridor development with lean six sigma approach: case in PT Jasamarga Related Business

Toll Corridor Development (TCD) is one of the businesses conducted by PT Jasamarga Related Business as a follow-up to the issuance of Peraturan Menteri Pekerjaan Umum dan Perumahan Rakyat (PUPR) No. 28 of 2021. In the development of its first TCD project, Jasamarga Related Business (JMRB) encountered issues that resulted in the delay of the project's completion. The purpose of this research is to analyze and make improvements to the causes of delays in the Taman Mini TCD project. In this research, the lean six sigma approach is used to analyze process improvements that can be carried out so that these problems can be minimized in the further development of TCD. To identify activities that cause delays in the implementation of this project, the critical path method (CPM) was used based on the results of interviews with those directly involved in the development of TCD project. From the activities that cause the delay, a causal analysis is carried out using a fishbone diagram, and then an analysis of possible improvements is carried out using a lean concept approach. Based on the analysis results, three main issues are identified, namely inadequate planning process, ineffective partner or consultant selection process and delays in construction completion. From the cause-and-effect analysis, it can be concluded that potential improvements can be made by implementing the concept of pull planning, improving the business process by reducing waste and enhancing value-added activities, establishing effective stakeholder management, and maximizing the use of technology-based applications to aid project control.