Lean Manufacturing Concepts Research Articles

Study of SME employees’ awareness level on lean manufacturing and ergonomics implementation in Malaysian and Indonesian production environments

SMEs are small to medium-sized businesses with relatively fewer workers and lower revenues than large companies. However, SMEs also contribute to the local economic growth of a region, so the smooth production process needs to be considered to increase productivity. Applying lean manufacturing (LM) and Ergonomics concepts in the production process is critical because it can overcome smooth production and maintain the health and safety of SMEs workers. LM focuses on minimizing waste, while ergonomics focuses on humans as a source of energy in the smooth running of production activities. So, this study aims to measure the level of understanding of Malaysian and Indonesian SMEs workers on applying LM and Ergonomics concepts on the production floor and determine the effect of these two concepts using the SPSS and SmartPLS4 applications. SPSS serves to measure the validity, reliability and mean for the category of workers' understanding of LM and Ergonomics. SmartPLS4 helps us understand the influence of the two concepts. Based on the calculation of the mean for each variable of LM and ergonomics, it is found that Malaysian workers understand enough compared to Indonesian SMEs workers. As for the effect, Ergonomics has a significant influence on LM.

Application of Selected Lean Manufacturing Tools to Improve Work Safety in the Construction Industry

Shaping safe and hygienic working conditions is the basic obligation of the employer. Employers are still looking for methods, tools, and solutions to improve work safety. The study reviews the literature on solutions aimed at improving occupational safety in construction. For this purpose, bibliometric analysis was used, consisting of the exploration and analysis of scientific studies in the field of occupational health and safety, including the possibility of using the LM tool to improve working conditions on construction sites. The study presents the possibility of implementing Lean Manufacturing (LM) tools in the construction industry. Their strengths and weaknesses were identified, and the benefits and possible barriers related to their effective implementation/use were identified. The result of the analyses was a summary of benefits for the construction industry (strengths and opportunities) as well as areas requiring improvement (weaknesses and hazards) regarding the LM tools used. Based on the conducted analyses, it was found that it is possible to use the tools of the LM concept to improve work safety and organize tasks performed on construction sites. The implementation of LM tools, such as 5S/6S, Poka-Yoke, and Standardization, enables risk reduction through a direct impact on the area being analyzed, in which occupational hazards have been identified. It is also noted that there is a need to simultaneously use LM tools (VM, Gemba-Walk, DHM) as solutions aimed at reducing risk.

The concept of lean manufacturing as a factor influencing the stable development of Russian companies

the research is aimed at analyzing the impact of the lean manufacturing concept on the stable development of Russian companies. The purpose of the study was to identify the relevance and significance of the use of lean production methods in Russian business, to assess the effectiveness of the introduction of Lean technologies at various levels of management and to analyze obstacles in their implementation. The research methodology was based on the analysis of statistical data, company reports and a comparative analysis of indicators before and after the introduction of lean manufacturing. The results of the study showed that the introduction of lean manufacturing helps to reduce costs, optimize production processes and increase the competitiveness of companies in various industries. The main tasks solved in the course of the study included an analysis of the causes and consequences of obstacles in the implementation of lean manufacturing, an assessment of the effectiveness of its application on the example of Russian companies in various industries and the identification of ways to further improve this practice. The findings can be used in the practice of enterprise management to increase production efficiency and optimize costs, which contributes to the sustainable development of the Russian economy. исследование направлено на анализ влияния концепции бережливого производства на стабильное развитие российских компаний. Целью исследования было выявление актуальности и значимости применения бережливых методов производства в российском бизнесе, оценка эффективности внедрения Lean-технологий на различных уровнях управления и анализ препятствий при их внедрении. Методология исследования основывалась на анализе статистических данных, отчетности компаний и сравнительном анализе показателей до и после внедрения бережливого производства. Результаты исследования показали, что внедрение бережливого производства способствует сокращению издержек, оптимизации производственных процессов и повышению конкурентоспособности компаний в различных отраслях. Основные задачи, решенные в ходе исследования, включали анализ причин и последствий препятствий при внедрении бережливого производства, оценку эффективности его применения на примере российских компаний различных отраслей и выявление путей дальнейшего совершенствования данной практики. Полученные выводы могут быть использованы в практике управления предприятиями для повышения эффективности производства и оптимизации затрат, что способствует устойчивому развитию российской экономики.

Financial Management Strategies for Implementing Lean Manufacturing in the Footwear Industry

The concept of lean manufacturing, initially developed to maximize resource utilization by minimizing waste, has evolved to address the needs of a rapidly changing and competitive business environment. Footwear industries face significant challenges and complexities that require a systematic and continuous response to maintain and enhance product value. Implementing lean manufacturing practices has become essential for these organizations to sustain and thrive in such a dynamic landscape. However, successful implementation is not solely dependent on operational adjustments but also on strategic financial management. This research examines the financial management strategies necessary for the effective implementation of lean manufacturing in the footwear industry. It emphasizes the importance of integrating financial planning with lean principles to ensure comprehensive and sustainable improvements. Key lean elements such as Value Stream Mapping (VSM), Cellular Manufacturing (CM), U-line systems, Line Balancing, Inventory Control, Single Minute Exchange of Dies (SMED), Pull Systems, Kanban, and Production Levelling are explored in detail. The study demonstrates how a focused approach to financial management can support these lean elements, enabling footwear companies to optimize resource allocation, reduce costs, and improve efficiency. By aligning financial strategies with lean manufacturing goals, organizations can achieve significant economic and operational benefits. This includes better cash flow management, investment in continuous improvement initiatives, and a robust framework for measuring the financial impact of lean practices. Through a comprehensive analysis of these financial strategies, the research provides valuable insights for footwear companies aiming to implement lean manufacturing successfully. It highlights the need for an integrated approach that combines financial acumen with lean methodologies to drive value creation, enhance competitiveness, and ensure long-term sustainability in the industry.

Experience of Implementation of the Lean Production Concept at the Enterprise of Thermal Insulating Materials Market

Relevance. The construction industry produces a third of global waste, much of it is not recycled, ending up in landfills and polluting the environment. Between 2000 and 2020, the volume of construction work has increased more than 12-fold. The flip side of the process is a proportional increase in waste. In the insulation materials market and in the construction industry in general, the relevance of the lean manufacturing concept is growing, as it can be used to reduce the amount of resources consumed and increase business efficiency.Purpose. This article considers the developed measures for implementation of the concept of lean production in the framework of strategic management of the enterprise at the plant of the market of thermal insulation materials.Objectives. Within the framework of the concept realization the excessive quality is reduced, the system of personnel training is implemented and the level of competitiveness of the enterprise is increased.Methodology. The object of the study is the plant of Belgorod region, the leader in labor productivity in the city of Belgorod. The works were carried out from 2021 to 2023.Results. Due to the implemented program labor productivity increased by 2,0%, the number of scrap was reduced from 1,7% to 0,8%, new strategies for the development of the company were developed due to the introduction of personnel training system.Conclusions. The program of increase of competitiveness of the enterprise of branch of heat-insulating materials on the basis of introduction of the concept of lean production at its projection on other companies given in the present article is perspective in the plan of increase of competitiveness of the Russian Federation in the world arena, in fact the economy of the country depends on efficiency of subjects functioning in it.

Industry 4.0 and Lean Manufacturing, using the MAUT Method

Industry 4.0 covers a wide range of areas, such as production processes, efficiency, data management, consumer relationships, and competitiveness. It is also becoming a topic of academic study, with researchers and scholars exploring various questions related to this revolution. Furthermore, the text mentions the Toyota Production System, which promotes efficiency and effective communication in production operations and introduces the concept of Lean Manufacturing, which aims to reduce costs and increase efficiency. The integration of Industry 4.0 with Lean Manufacturing is referred to as “Lean 4.0”. The method used in this article was a questionnaire sent to manufacturing companies in southern Brazil and analyzed the data obtained through the Multi-Attribute Utility Theory (MAUT), which is presented as a decision-making tool that allows comparing alternatives taking into account multiple criteria. The conclusions of this study show that both the views of senior management and those surveyed consider that the companies involved in this research will be in 5 years, with their Industry 4.0 well developed. On the Lean Manufacturing side, considering only the view of those surveyed, they consider that the companies involved in this study will be in 5 years, with Lean Manufacturing quite developed. The practical contribution of this study shows that the companies participating in the study are committed to adopting advanced manufacturing technologies and practices. This conclusion is important because it indicates that companies are aware of the opportunities and challenges of Industry 4.0 and Lean Manufacturing.

Evaluating the effectiveness of an algorithmic strategy for implementing the Lean concept using modern innovative tools

The subject of the study is a methodological toolkit that allows evaluating the effectiveness of the processes of implementing elements of a lean production system. The object of the study is small (micro) enterprises that provide transport and logistics services and implement elements of a lean manufacturing system. The purpose of the study is to develop methodological tools that are simple enough to be used in conditions of limited capabilities of small and micro enterprises in the field of transport and logistics services. The author examines in detail such aspects of the topic as issues related to determining the effectiveness of the processes of implementing the concept of lean manufacturing, which always remain in the focus of attention of researchers and remain relevant. At the same time, most modern methodological developments require the use of a set of rather complex and time-consuming calculations that are appropriate for use in large and medium-sized companies, while for small, and especially micro-enterprises, these recommendations may be unacceptable. The research methodology includes a systematic approach, conceptual modeling, graphical, comparative and statistical analysis, the combination of which allowed us to achieve the necessary level of factual reliability and reasonableness of conclusions. The main conclusions of the study are that the introduction of individual elements and tools of lean manufacturing in accordance with the stages of the proposed system algorithm (algorithmized strategy) significantly increased the productivity of the company's employees and increased the number of customers served, as well as led to changes in other economic indicators. A special contribution of the author to the research of the topic is the construction of a conceptual model of the Transport and logistics system (TLS) of the enterprise, which includes specially developed in accordance with the individual characteristics of the organization: the idea, goals, objectives, six basic principles of building a TLS, eight principles of forming a lean approach, a basic set of tools and methods, organizational and managerial culture, a list of basic potential losses, a seven-stage sequential system implementation algorithm (algorithmized strategy) and transport and logistics flows. The scientific novelty consists in the development of an improved method for evaluating the effectiveness of key elements of an algorithmized strategy for implementing lean manufacturing tools in small (micro) businesses based on an integrated approach through the development of a system of criteria including commercial and qualitative indicators.

Lean manufacturing + healthcare= lean healthcare, a way to optimize efficiency in the healthcare sector

The concept of Lean Manufacturing arises within the Toyota Production System (TPS) with the aim of eliminating all activities that do not generate value to enhance and increase productivity. Lean Manufacturing is applied in the West, and the concept transforms into Lean Manufacturing (LM). This concept no longer belongs solely to the automotive sector; all its tools have now migrated to all activities of daily life. An important application, particularly in dealing with human lives, is in the healthcare sector, specifically in hospitals. This gives rise to the concept of Lean Healthcare, which has broad applications, often resulting in process improvements, the elimination of non-value-generating activities, and better resource management.

USING THE LEAN MANUFACTURING METHODOLOGY TO IMPROVE THE QUALITY OF THE ENTERPRISE'S BUSINESS PROCESSES

Formulation of the problem. In the conditions of global competition, lean production acquires special importance. For enterprises all over the world, the only way to survive in the market is to produce goods and provide services that most fully satisfy the demands of consumers, while using advanced management methods and technologies. Lean manufacturing is one of the modern tools of production organization and management technology, which is used to improve the quality of products and services, the most complete satisfaction of consumer needs, while ensuring a careful attitude to the company's resources and their savings.
 The purpose of the study is the further development of methodological, methodical and practical approaches to the concept of Lean manufacturing to improve the quality of the enterprise's business processes.
 Research methods. The research used scientific methods, such as theoretical generalization, comparison, analysis, synthesis.
 Result. In the process of research, a comparison of traditional business management and the concept of lean production was made and revealed. that the concept of lean production has such advantages as the transition from centralized, vertical management to horizontal, involvement of all employees in the process, teamwork, focus on rational use of resources. The concept of lean production is aimed at eliminating the following main types of losses: overproduction of goods; waiting for raw materials, semi-finished products, necessary service information; unnecessary movement of materials; redundant processing steps arising due to errors in the design of business processes; excessive stocks and business processes leading to their occurrence; unjustified rotation of personnel in the work process; production of waste; underutilization of employees' creative potential.
 Conclusions. Six main elements and 52 components (requirements) of Lean manufacturing are defined based on the SAE J4000 standard for more successful application of lean manufacturing ideas in practice production to analyze the levels of implementation of lean manufacturing methodology components and elements. The main elements of the concept of lean manufacturing, the development and improvement of which should be focused on, are: company management and trust in it; enterprise personnel; information environment; chain "supplier – organization – consumer"; product; business processes. An important role in the concept of lean manufacturing is played by the 5S ordering system and the system of general maintenance of TPM equipment .
 Keywords: lean manufacturing; losses; flow of value creation; 5S ordering system; system of general maintenance of TPM equipment; SAE standard J4000.

Solving organizational problems using “X-TRIZ” technique: empirical study

Today, evolution of science and technology has reached tremendous rate. Major breakthroughs in sciences, technology, medicine, and engineering make our everyday life more and more comfortable. The TRIZ approach is a powerful yet creative approach for solving problems and for addressing difficult situations in different fields of life. Its strength lies both in (1) its ability to state solution goals, and (2) its ability to identify high-level solutions to complex problems. According to these phenomena, the authors are attempting to is considered the the basic postulates and principles of the theory of TRIZ in inventive problem solving to improve the performance and efficiency of the organization. It has been proved that TRIZ technique successfully used as a signified tool for optimizing production and services processes. Meanwhile, this technique highly matched when considering the concept of lean manufacturing, which requires a particularly detailed analysis in terms of resource savings. This paper is devoted to the development of a modern xTRIZ based on the construction of a perfect entire organizational system, which subsequently has a positive impact on the performance of an industrial organization. To demonstrate the xTRIZ, real field studies were conducted to identify the effectiveness of an innovative project.

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.

Lean manufacturing and quality management: Ways to improve efficiency

The reasons for the growing interest in lean manufacturing and quality management systems in engineering production systems are considered. It is shown that these systems currently work without proper efficiency. The essence of lean manufacturing and quality management concepts is considered. The main errors in their understanding and application are analyzed. It is established that it is expedient to implement these systems on the basis of research of processes of the organization's activity. The hierarchy of organizational and technological systems is considered and the main tasks solved within the lean manufacturing and quality management systems are presented. The tools of lean manufacturing and quality management are offered, which it is expedient to use in providing highly efficient machine-building production. Suggestions for restructuring of engineering departments of machinebuilding enterprises are given.

Optimizing Carbon Footprint and Operational Productivity of Horizontal Boring Machines: An EFBA-Based Approach

In modern-day industries, the presence of bottleneck processes, where the throughput capacity falls short of the workload, can result in reduced efficiency, increased energy consumption, and higher production costs. Such inefficiencies are deemed unacceptable in today’s highly competitive market, coupled with stringent environmental regulations. To address these challenges, many industries have adopted lean and green manufacturing concepts to enhance workflow and environmental performance. This research paper integrates bottleneck analysis with carbon footprinting, specifically employing the EFBA (Energy Focussed Bottleneck Analysis) approach, to identify and eliminate bottlenecks and high energy consumption within the machining section of a press manufacturing industry. The study focuses on improving the setup time, machining time, and carbon footprint associated with the boring operation of the journal head. By implementing the proposed approach, significant improvements were achieved, with setup time reduced by 108 min, machining time reduced by 64 min, and carbon dioxide emissions reduced by 32.2 kg. These outcomes highlight the effectiveness of the integrated EFBA-based methodology in enhancing operational efficiency and reducing the environmental impact of the manufacturing process. The findings of this study offer valuable insights and practical implications for other industries seeking to optimize their production systems, reduce energy consumption, and minimize carbon emissions. By identifying and addressing bottlenecks through a combined bottleneck analysis and carbon footprinting approach, companies can enhance their operational productivity while promoting sustainability in line with environmental regulations and market demands.

ВНЕДРЕНИЕ БЕРЕЖЛИВОГО ПРОИЗВОДСТВА НА РОССИЙСКИХ ПРЕДПРИЯТИЯХ

The article is a study devoted to the analysis of the process of introducing the lean manufacturing concept at Russian enterprises. The author summarizes the conceptual foundations of Lean technology: fundamental principles, main types of losses, tools and implementation algorithm. Based on the analysis of data from the Federal Competence Center, the activities of the most successful Russian enterprises that joined the national project “Labor Productivity” were analyzed. Despite the positive experience of implementing lean production, confirmed by the achievement of economic effect, the author identified the main problems in the implementation process: insufficient involvement of the top management of the enterprise and a superficial understanding of the values of the philosophy of lean production, the absence or insufficient understanding by staff of the feasibility of introducing lean production and proposed specific ways to solve them. Based on the results of the study, it was concluded that the efficiency of industrial enterprises that have implemented lean production tools and methods has increased and the relevance of introducing the concept of lean production in the social sphere has been identified.

Shaping safe and hygienic working conditions from the perspective of implementing the assumptions of the lean manufacturing concept

Shaping safe and hygienic working conditions from the perspective of implementing the assumptions of the lean manufacturing concept

ИННОВАЦИОННЫЕ МЕТОДЫ, ПОВЫШАЮЩИЕ ЭФФЕКТИВНОСТЬ БЕРЕЖЛИВОГО ПРОИЗВОДСТВА В РОССИЙСКОЙ ПРОМЫШЛЕННОСТИ

The article is devoted to the study of the features of the application of the lean manufacturing concept in Russian industry. Particular attention is paid to the possibility of increasing labor productivity using traditional and innovative methods of continuous improvement of business processes in industry. The purpose of this article is to study the concepts of lean production as a factor in increasing labor productivity of Russian companies and to develop innovative methods that increase the efficiency of lean production. As part of the study, an assessment was made of the impact of the implementation of the National Project “Labor Productivity” on the growth of industrial efficiency, the dynamics of the productivity index from the moment the measures began state support. The regions leading in productivity growth and the regions of the Central Black Sea Region are considered. The results of the study show that in general, for the type of economic activity “Manufacturing”, the growth rate of the labor productivity index is negative during the implementation of the national project; there is only a jump in 2020. It is suggested that this is not related to the implementation of the project, but to the general crisis bifurcation situation in economics.
 The article shows that the experience of those regions that have achieved success despite the general socio-economic instability in the country and industry deserves a closer look. Summarizing best practices, the article systematizes the main methods of lean production, paying special attention to innovative methods that can be used not only in industry, but also in all types of economic activity. A survey was conducted of the opinions of specialists representing a number of industrial enterprises of the Central Black Sea Region involved in the implementation of the National Project “Labor Productivity”, this made it possible to generalize productive methods of lean production and identify the main problems in applying the concept of lean production in Russian industry.

Study of the discipline «Lean Manufacturing» as a condition for training specialists for the industrial sector of the economy

Personnel training using the tools and algorithms of the lean manufacturing concept is relevant, since improving the efficiency and competitiveness of enterprises is a key issue in the development of the industrial sector of the economy. The main condition for the successful implementation of this methodology is the availability of professional competencies among specialists implementing lean manufacturing at enterprises. Updating the curricula for the preparation of undergraduates, as well as the introduction of a new discipline into the educational process, will make it possible to form a specialist who is ready to work in a lean production environment. At the Department of Innovation in Chemical Technology of Kazan National Research Technological University, the discipline «Lean Manufacturing» has been introduced into the curricula of undergraduates studying in the field of Innovation. In order to identify the formation of knowledge, skills and abilities for the implementation of Lean-methodology, as well as the possession of its tools and algorithms for implementation at enterprises, the authors of the article conducted a questionnaire survey, which showed that a systematic approach is needed to form students' competencies in the field of lean manufacturing to increase their competitiveness in the modern labor market. Studying the discipline «Lean Manufacturing» will allow to form the necessary competencies in the field of Lean-methodology implementation at enterprises and increase labor productivity.

Contribution of Lean Manufacturing on environmental performance in Moroccan Industry

In the context of globalized competition, sustainable development has become a crucial goal for manufacturers, necessitating a balance between economic, environmental, and social factors. The evolution of production system efficiencies and government policies has been pivotal in mitigating the environmental impact of manufacturing activities. This paper explores the role of Lean Manufacturing in enhancing environmental performance within organizations. It presents the concept, tools, and models of Lean Manufacturing, discussing its contribution to environmental sustainability. The paper bases its findings on a literature review and validates them through two case studies in Morocco. The first case study examines the implementation of Lean tools in a Tangier-based company, highlighting significant reductions in waste and energy consumption. The second involves interviews with managers from Moroccan automotive industries, revealing a positive correlation between Lean practices and environmental performance. The conclusion drawn is that Lean Manufacturing not only reduces pollution and energy consumption but also boosts productivity, thus aiding companies in becoming more profitable and environmentally responsible.

Unlocking circular economy potential: evaluating production processes through circular value stream mapping in real case studies

PurposeThe purpose of this study is to propose a new mapping tool called Circular Value Stream Mapping (C-VSM) that combines Circular Economy principles with Lean tools to enhance sustainability performance in operations.Design/methodology/approachTo develop the C-VSM tool, the researchers conducted a literature review and a focus group. The tool was then applied to two real case studies in the agri-food sector, specifically analyzing an artichoke and olive oil producer, to assess its validity and effectiveness.FindingsThe study introduces the Circular Resource Box (CRB) as a key innovation in the C-VSM tool. This visual representation effectively captures resource circularity and how resources and wastes are managed, making it easy to identify circularity in the production process. By combining qualitative and quantitative information with this visual representation, companies can identify improvement opportunities aligned with the CE.Research limitations/implicationsThe research is limited in scope as it focuses on the application of the C-VSM tool in the agri-food sector. Further research could explore its applicability in other industries and settings to understand its broader impact.Practical implicationsThe C-VSM tool provides practical benefits to companies seeking to transition from linear to circular production processes. It enables practitioners to identify opportunities to reduce environmental impacts and optimize production operations in line with CE.Originality/valueThe introduction of the C-VSM tool is a novel approach that bridges the gap between Lean Manufacturing and CE concepts, advancing the understanding of how CE thinking can be effectively implemented in operations.

Foreign experience in managing a high-tech company using the concept of lean manufacturing (on the example of Boeing)

Foreign experience in managing a high-tech company using the concept of lean manufacturing (on the example of Boeing)