Lean Environment Research Articles

A conceptual framework for integrating Facility Layout and Production Scheduling in Flowshop Manufacturing Cells decisions

Objective: In this paper, a conceptual framework for integrating production scheduling in flowshop manufacturing cells, known as flowshop group scheduling (FSGSP), and unequal-area facility layout (UAFLP) decisions is proposed. Materials and Methods: First, a brief literature review is carried out to identify the elements, solution techniques and complementary decisions for the UAFLP, FSGSP and layout-scheduling approaches. Results: Based on the results of the literature review a 4-phase integrative model is proposed to integrate these decisions, based on a lean manufacturing environment. The phases include the input data collection and preparation process, the definition of the UAFLP, FSGSP and other complementary decisions, the optimization of the decisions, and the selection of the best alternative. Conclusions: The integration of these decisions using the proposed framework can achieve benefits related to the reduction of mudas, such as material handling, high work-in-process inventory levels and setup times for real, industrial contexts.

Project scheduling in a lean environment to maximize value and minimize overruns

Project scheduling in a lean environment to maximize value and minimize overruns

Implementation of Lean Management Practices in Azerbaijan: On the Example of a Private Company

Organizations are facing crucial modifications as global market and conditions change day after day. To keep up with fast changing realities, it's important to apply innovation decisions to the current stage of organizations. Lean management consolidates tools and techniques to revert from traditional way of operating to the new human oriented one. In the carried-out research its outlined, human resources management plays a big role in spreading and supporting lean initiatives. It was suggested that, Lean and Human resources management are compatible and should work together to obtain sustainable success by implementation of an innovation approach such as Lean. Both lean management and human resource management focus on the same goals with different methods in terms of control of businesses. All positivist approaches and practices are included in these approaches and practices, which are developed with a focus on the interests of the community, in order for the process to be concluded positively. The employee-centred management approach of human resources management is crucial to lead and maintain good environment in the teams. For this reason, in the lean management philosophy, it is aware that the corporate structure has responsibilities in terms of training the employees, eliminating their problems and supporting them in struggling with the responsibilities they undertake. This paper is quantitative, online survey has been conducted with employees of a private company in Azerbaijan and results were analysed in statistical analysis software SPSS and relevant suggestions and recommendation were given for reorganization to enable lean friendly environment on a sample of the given company.

Integrating Lean and Sustainable Manufacturing Principles for Sustainable Total Productive Maintenance (Sus-TPM)

Abstract Total productive maintenance (TPM) is a systematic method to ensure equipment can function at the required performance to meet customer demand. The benefits of TPM are well known in lean manufacturing environments, and the technique is widely used to ensure no waste is created by defective equipment. Lean manufacturing principles and practices provide a solid basis to build upon to create more sustainable products, processes, and systems. TPM practices, therefore, can serve as a useful tool for more sustainable maintenance practices, leading to more sustainable manufacturing when additional criteria are incorporated into the existing foundation of the practice. This paper introduces a framework to integrate sustainability criteria and develop Sustainable TPM (Sus-TPM) as a complement to TPM practices. The approach to visually present the temporal sustainability performance variation of equipment by developing impact assessment trees using the Sus-TPM technique is presented. The application of the approach to an example is provided to demonstrate its benefits. Potential future expansions are also discussed to highlight how the Sus-TPM methodology could become an important tool for more sustainable manufacturing.

Study on the combustion performance of nano/micro-sized aluminum powders regulated by polydopamine interface

Aluminum powder with a high specific impulse, high stability, and adjustable reactivity is widely used in the aerospace field. However, most current research focuses on the single sized nano-(n) or micro (µ)-aluminum (Al) powders. The synergistic effect between multi-scale Al powders was ignored. In this paper, firstly, the n-µAl powders were modified by polydopamine (PDA) as the interface layer, then they were further modified and encapsulated by polytetrafluoroethylene (PTFE) and ammonium perchlorate (AP). The effects of PDA interface structure and fluoride compounds on the combustion performance and agglomeration of Al were studied in the lean oxygen environment. The results show that the ration methods of PDA-modified nAl mixed with µAl yields satisfactory results. The thickness of PDA interface layer on the surface of nAl powder is positively associated with the concentration of mixed solution of dopamine hydrochloride. The PDA interface layer not only regulates the thermal reactivity of modified sample by reducing the decomposition temperature and rate of AP, but also has a significant impact on the flame diffusion and combustion intensity. The synergistic effect of PDA interface layer, PTFE, and n-µAl powders can significantly inhibit the agglomeration of Al particles during combustion.

A nanosecond pulsed discharge circuit model for engine applications

Non-equilibrium plasma discharges in spark gaps have been an increasingly studied method for alleviating cycle to cycle variation in lean and dilute combustion environments. However, ignition models that account for streamer propagation, cathode fall, and transmission line amplification over nanosecond time scales have so far not been developed. The present study develops such a model, with emphasis on the energy delivered from circuit to cylinder. Key pieces of the relevant physics and chemistry are summarized, simplified, and systematically coupled to one another. The set of parameters is limited to a handful of key observables and modeled using Modelica. Results show non-trivial behavior in the energy delivery characteristics of such discharges with important implications for ignition.

Analysis of deviation from nominal control chart performance on short production runs

Paper aims This paper studies the influence of process variation on deviation from nominal control chart performance and proposes some adjustments on the control limits to make it enable on small batches. Originality Specific methods were developed to monitor small batches, mainly due to unavailability of data for precise parameters estimation, like the deviation from nominal control charts. However, Montgomery (2014) highlights some essential aspects, such as the influence of process variation on its performance. Research method The method used was mathematical modeling and computer simulation. Main findings The results validated that there is a significant influence of the process variation on the control chart performance. It has been demonstrated that small adjustments on the control limits can make it enable on lean environments. Implications for theory and practice The main contribution is demonstrating the use of deviation from nominal control chart, through the valid control limits definition regardless of the samples size.

Customized Lean 3D Simulation Environment for Intralogistics

Customized Lean 3D Simulation Environment for Intralogistics

The quality management process of a fish processing enterprise in a lean production environment

The quality management process of a fish processing enterprise in a lean production environment

"Feels Good to Get Wet": The Unique Affordances of Surf Therapy Among Australian Youth.

Increasing prevalence rates of mental health problems among adolescents is an issue of growing concern. Surf therapy is a novel intervention that may provide tangible benefits to address this problem. Congruent with the ecological dynamics perspective (EDP), the existing research postulates that surf therapy yields psychological benefits in part due to the unique affordances of immersion in a blue space such as the ocean. Evidence worldwide has validated the use of surfing as a therapeutic mediator to achieve positive change, however, no such research has been conducted on Australian adolescents. The current study aimed to evaluate the impact of the Waves of Wellness (WOW) Foundation's 8 week surf therapy program on mental health outcomes in Australian at-risk youth. The study employed a mixed-methods design to examine the experiences of participants. Nine adolescents (Mage = 14.9; SD = 1.2; 8 female) participated in the quantitative stage, with four completing the qualitative interview. Results indicated positive changes in resilience, self-esteem, social connectedness, and depressive symptoms post-intervention, however, improvements were not maintained at follow-up. Participants unanimously agreed that the program normalised their experiences with mental health through the unique leaning environment and fostered personal growth through mastery experiences and the development of healthy relationships. The EDP provided the most compelling explanation of the results denoting that benefits arise from the reciprocal relationship between individual, task, and environment. Despite the small and heterogenous sample, the findings provided preliminary evidence of the efficacy of surf therapy among Australian youth and offer a potential starting point for further research utilising larger more diverse samples.

The driving and dependence power between Lean leadership competencies: an integrated ISM/fuzzy MICMAC approach

Lean Manufacturing (LM) is about cultural change at all levels of an organization, which can be seen as the essence of leadership. This study aims to present a list of the main Lean leadership competencies with validated definitions and propose a practical roadmap to Lean leadership development and training. A Systematic Literature Review (SLR) was conducted to achieve this goal in which the Lean leadership competencies were identified. The Interpretive Structural Modelling (ISM) approach established the relations among the leadership competencies and result in a structural model that could be used for Lean leadership development. The analysis of leadership competencies' driving power and dependence power was done using the fuzzy Matriced’ Impacts Croisés Multiplication Appliquée á un Classement (MICMAC), which improved the reliability of research. This study contributes to Lean leadership literature by proposing a validated roadmap to Lean leader development and training. A structural model was developed that shows the hierarchy among the competencies and indicates the ones that should be prioritized. Besides, the result shows that the main ways to improve a Lean leader are attending to the shop floor and developing self-awareness. Furthermore, a strong synergy among all competencies was observed, reinforcing the fact that Lean must be an endless journey of improvement. To the best of our knowledge, our study is the first to present the relationship between Lean leadership competencies. In addition, the results may guide the development of new leaders who work in Lean environments.

First of Its Kind Automotive Catalyst Prepared by Recycled PGMs-Catalytic Performance

The production of new automotive catalytic converters requires the increase of the quantity of Platinum Group Metals in order to deal with the strict emission standards that are imposed for vehicles. The use of PGMs coming from the recycling of spent autocatalysts could greatly reduce the cost of catalyst production for the automotive industry. This paper presents the synthesis of novel automotive Three-Way Catalysts (PLTWC, Pd/Rh = 55/5, 60 gPGMs/ft3) and diesel oxidation catalysts (PLDOC, Pt/Pd = 3/1, 110 gPGMs/ft3) from recovered PGMs, without further refinement steps. The catalysts were characterized and evaluated in terms of activity in comparison with benchmark catalysts produced using commercial metal precursors. The small-scale catalytic monoliths were successfully synthesized as evidenced by the characterization of the samples with XRF analysis, optical microscopy, and N2 physisorption. Hydrothermal ageing of the catalysts was performed and led to a significant decrease of the specific surface area of all catalysts (recycled and benchmarks) due to sintering of the support material and metal particles. The TWCs were studied for their activity in CO and unburned hydrocarbon oxidation reactions under a slightly lean environment of the gas mixture (λ > 1) as well as for their ability to reduce NOx under a slightly rich gas mixture (λ < 1). Recycled TWC fresh catalyst presented the best performance amongst the catalysts studied for the abatement of all pollutant gases, and they also showed the highest Oxygen Storage Capacity value. Moreover, comparing the aged samples, the catalyst produced from recycled PGMs presented higher activity than the one synthesized with the use of commercial PGM metal precursors. The results obtained for the DOC catalysts showed that the aged PLDOC catalyst outperformed both the fresh catalyst and the aged DOC catalyst prepared with the use of commercial metal precursors for the oxidation of CO, hydrocarbons, and NO. The latter reveals the effect of the presence of several impurities in the recovered PGMs solutions.

Lean Companies Employed Assembly Workers Train with New Approches

LM has proven itself the production system that enhances shop floor efficiency. Furthermore, the current environment for production firms is accelerating the pace at which LM is implemented. The manufacture of lean is not easy to introduce. It is constant and complex activity. Assembly workers in production processes are the core of lean manufacturing activity. Training is known as vehicle to aid the implementation process. While the importance of training is known so far, there are only a few options for organizing effective training. The results of the survey of questions conducted inside UK manufacturing companies are examined. This article illustrates the definition of lean production and worker requirements in lean environment.

Prevalence and patterns of musculoskeletal pain among undergraduate students of occupational therapy and physiotherapy in a South African university.

Background:Musculoskeletal pain (MSP) conditions are common in the educational leaning environment and are often associated with poor ergonomic conditions.Objective:This study investigated the prevalence, pattern and possible risk factors of MSP among undergraduate students of occupational therapy and physiotherapy in a South African university.Methods:A cross-sectional survey using an internet-based self-designed electronic questionnaire was used to obtain information about participants’ socio-demography, ergonomic hazards, MSP, and relevant personal information. Descriptive statistics, chi-square, and logistic regression were used in analyzing the data.Results:There were 145 participants (females 115 (79.3%); physiotherapy (74) 51.03%), making 36.7% of the present undergraduate student population in the two departments. The most prevalent ergonomic work hazards were prolonged sitting (71.7%) and repetitive movements (53.8%). The 12 months prevalence of MSP among the students was 89.7%. The pattern of MSP revealed that pain on the neck region was most prevalent (66.2%) followed by pain in the low back region (64.4%). Duration of daily travels and participation in regular exercise activities were significantly associated with the prevalence of MSP. Logistic model explained 23.6% of the variance in prevalence of MSP and correctly classified 94.1% of cases (, ). The right-handed students were 0.13 times more likely to present with MSP than left-handed students. Also, students who exercised regularly were 9.47 times less likely to present with MSP.Conclusion:MSP is highly prevalent among health science undergraduates and is significantly associated with sedentary postures and inadequacy in structured physical activity participation.

Forecasting Structural Equation Modelling of Lean Manufacturing using High Order Statistical Functions

Typically, the primary goal of lean technology (LT) is to improve profits and create value by minimising waste. The consideration of demand variability in a multi-dimensional lean manufacturing environment is an innovation in production system engineering. However, manufacturing systems that fail to recognise demand variability generate high work-in-process (WIP) and low throughput in the lean manufacturing process. Moreover, many companies have found it difficult to successfully implement and sustain lean manufacturing. It is, therefore, very important for companies to identify and understand the critical success factors for successfully implementing lean manufacturing. To overwhelm the challenges in the implementation of lean manufacturing, this paper plan to introduce an advanced model and this model is analysed using structural equation modelling.

Strategies for Inculcating Life Skills in CBSE Schools of Varanasi City

Life Skills Education is a value addition programme for children and youth to understand self and enable them to analyze their capacity to enhance the function in most productive way so they empower efficiently in challenging situations. Life Skills include psychosocial competencies and interpersonal skills that help people make informed decisions, solve problems, think critically and creatively, communicate effectively, build healthy relationships, empathize with others, and manage their lives in a healthy and productive manner. Life Skills are needed at all stages and phases of life, but it becomes important for children and adolescents because this is crucial stage on which future of individual depends. The Life Skills programme is a very important and integral part of the educational system worldwide. It is a school based programme where Life Skills are imparted in a supportive learning environment. The Central Board of Secondary Education (CBSE), India has introduced Life Skills Education as an integral part of its curriculum and provides guidelines for transaction of the ten core Life Skills. Though Life skills are often learned indirectly through experience and practice but it would be enhanced directly by implementing through a dedicated Life skills curriculum by using proper and suitable transaction methods. In school based programme to teach Life Skills in supportive leaning environment teacher’s role is very crucial. Teachers should be act as positive role models for students as Life Skills are better caught then taught. So it is significant to know what strategies teachers build to inculcate the Life Skills among students. The present paper focuses on the ten core Life Skills necessary for students and the strategies used by CBSE teachers at upper primary level of Varanasi City to transact and internalize these Life Skills among students. Survey method was used for the study. Sample consisted of 225 teachers teaching at upper primary level from 31 CBSE schools selected purposively. Content analysis was used to analyse data obtained from questionnaire prepared by reseacher, frequency and percentage were calculated. The findings provide information regarding strategies practiced by CBSE teachers would be helpful for designing Life Skills Training Module.

An empirical investigation on association between human factors, ergonomics and lean manufacturing

Most adopters focussed on lean tools and techniques (hard lean practices) alone and neglected human factors and ergonomics (soft lean practices) while implementing lean in an organisation. The implementation of hard lean practices alone worsens workers’ Quality of Work Life (QWL) which results in obtaining anticipated long-term lean performance. To promote the adaptation of soft lean practices, the study aimed to highlight the significance of Human Factors and Ergonomics (HFE) in lean performance and sustainability through structural equation modelling using survey data from 168 experts involved in lean environments. The study documented that the degree of lean performance is positively related to HFE. Also, it found that psychosocial and physical factors influence lean performance enhancement more than others do whereas cognitive factors influence them the least. The study will help managers and researchers understand the relationship between HFE and lean performance and thus help to solve human-related issues in a lean environment and lean system design for successful implementation. Finally, the implications, limitations and future scope of the study are discussed elaborately.

Migration and transformation characteristics of zigzag char-N in lean oxygen environment

The migration and transformation of N in zigzag char-N with the presence of high concentration NO in the reduction zone is investigated by quantum chemistry method. Transformation characteristics of N in lean oxygen environment are systematically calculated from the molecular level by constructing a char-N model containing a hydroxyl group. The results show that NO in the reduction zone can combine with N in the char to form N2; and the presence of oxygen enhances the char chemical activity and further promotes the release of N in the char. The co-existence of oxygen and NO in the reduction zone makes the release of N and the combustion of C occur simultaneously, which is manifested by NO and N in the char combining to form N2, and at the same time oxygen and C in the char formation CO2 or CO. The kinetic calculations of the rate-limiting step rate constants of the C combustion products show that C is easily oxidized to CO under low temperature and lean oxygen conditions, and with the temperature rise the CO2 generation rate increases significantly and the high temperature is conducive to CO2 formation.

The Effect of in Situ Phenol Hydrogenation with Raney Ni on the Fate of Hydrogen from Glycerol Aqueous Phase Reforming

The fate of hydrogen during glycerol aqueous phase reforming (APR) and the effect of in situ phenol hydrogenation (IGAPH) with Raney Ni on the glycerol APR mechanism were studied. Glycerol APR proceeds through parallel routes via 1,2-propylene glycol or ethylene glycol. Combining phenol hydrogenation with glycerol APR changes the distribution of hydrogen among products. Hydrogen for hydrogenolysis of glycerol APR intermediate products was diverted to phenol hydrogenation, leading to enhanced glycerol conversion and suppressed hydrogenolysis. This hydrogen transfer occurred on the catalyst surface without formation of hydrogen gas as indicated by empirical results from open/closed system reactors. The lean hydrogen environment induced by hydrogen scavenging phenol on Raney Ni promoted the ethylene glycol route generating additional hydrogen for phenol hydrogenation. Moreover, removal of CO2 by adjusting process pressure in the open system can enhance phenol conversion during IGAPH and eliminate the burden of operating at autogenous high pressure. In addition to producing renewable hydrogen from glycerol and water, in situ APR-hydrogenation eliminates the transport barrier of gaseous hydrogen diffusion into solution.

Lean Production implementation, Cloud-Supported Logistics and Supply Chain Integration: interrelationships and effects on business performance

PurposeWith support from the dynamic capabilities theory, this paper examines the role of Cloud Computing technology use in logistics (Cloud-Supported Logistics) and its effect on business results in Lean manufacturing management (Lean Production implementation) and Supply Chain Integration contexts.Design/methodology/approachUsing the survey method, a random sample of 260 companies in intermediate positions in their supply chains was gathered from a population of 1,717 Spanish companies and used to test five hypotheses. The data were collected by telephone survey using a computerised system with a response rate of 15.6% (260 valid questionnaires). Structural equation modelling was used to test the five proposed hypotheses.FindingsThe findings indicate that Cloud-Supported Logistics use plays an important role in achieving better business results in Lean Production environments. Lean Production has been found to have both a direct effect and an even more powerful indirect effect on performance through the Cloud-Supported Logistics and Supply Chain Integration that these technologies produce. Supply Chain Integration is also found to have a mediating effect in the Cloud-Supported Logistics–performance relationship.Originality/valueThis study is valuable for academics and practitioners as it provides evidence of the relevant role played by Cloud-Supported Logistics in Lean Production implementation contexts. Cloud-Supported Logistics and Lean Production are strategically and operationally linked and their joint use results in Supply Chain Integration and better business performance.