Lean Manufacturing Implementation Research Articles

Assessment model of lean effect (AMLE)

PurposeThe purpose of this paper is to present the “Assessment Model of Lean Effect” (AMLE), a theoretical model that measures Lean manufacturing implementation effect over the global performance of a company.Design/methodology/approachAMLE model is divided in two criteria types: the “Facilitators criteria” and the “Results criteria”. “Results criteria” are inspired from the European Foundation for Quality Management (EFQM), Global Reporting Initiative (GRI) and ISO 26000. The “Facilitators criteria” are based on the main philosophy of the Lean manufacturing, which is the total elimination of all types of waste. The development of the scoring scale was based on the results, approach, deployment, assessment and review (RADAR) philosophy and the experience of nine consultants from the automotive field; the choice of the consultants was based on three conditions. Furthermore, each consultant has his\\her own weight according to its expertise. Lastly, the AMLE was validated via a case study set in an automotive industry company called FEBA. The validation process is divided in two different steps: the first step is related to Facilitators assessment and scoring; via the evaluation of the different projects implemented by FEBA to eliminate the different types of waste. The second step concerns Results assessment and scoring, via the evaluation of the performance measurements used by FEBA to assess the effect of the Facilitators' implementation.FindingsThe developed model (AMLE) enabled the Lean manufacturing effect assessment on the global performance of a firm from the automotive field. The case study results reveal that the aforementioned firm does not give priority to social measurements. Consequently, the performance of the firm was negatively impacted.Research limitations/implicationsThe criteria of AMLE are inspired from the definition of the Lean manufacturing given by Taiichi Ohno, from ISO 26000 and from GRI; meaning that these criteria could be adjusted if other references existed or developed. In addition, the scoring rules are established according to the experience of a limited number of consultants from the automotive field. The scoring rules establishment would lead to meaningful outcomes, if the number of participants was increased. During the assessment of the global performance, the perception of the auditor plays an important role in terms of scoring because the scoring rules allow the possibility to the auditor to give from the minimum to the maximum of the score, according to his perception and experience. For the case study, the validation of the developed model requires starting with the “Facilitators” implementation process and then measure the generated global performance. However, due to time constraints and limited opportunities for new projects, the validation was based only on existing projects managed by the firm. To address the study limitations, it is envisaged to detail and explain the scoring rules while extending the number of consultants. Furthermore, the assessment of Lean manufacturing global performance through the AMLE model may be subjective and requires a mathematical modeling. In fact, the Lean manufacturing performance assessment via the developed model could have a degree of subjectivity; that is why the design of a mathematical model seems required.Practical implicationsThe research findings may direct practitioners and decision makers to the importance of assessing the global effect of the Lean manufacturing on the overall performance of the firm. The AMLE model is a tool allowing the assessment of Lean manufacturing effect over economic, environmental and social performances.Originality/valueThe developed model is the first one assessing the global performance generated by the elimination of waste via the application of the Lean manufacturing.

Implementation of Lean Manufacturing to Improve Air Handling Unit Coil Manufacturing in Saudi Air Conditioning Manufacturing Company (SAMCO)

This report aims to improve the production operations of the coils shop of air handling units (AHU) at Saudi Air Conditioning Manufacturing Company (SAMCO) by applying lean manufacturing strategy. The coils shop of AHU experienced several issues which impact negatively on its performance and increase the non-added values. For instance, it suffers from significant amount of scrap, low machines utilization, extra manpower, long machine set up time, and the absence of process safety system. In this report, the required data were collected by three ways; observation, recording and conducting the interviews with the related people. These data were analyzed by a wide range of tools, which are used to apply lean manufacturing such as, value stream mapping, 5S, work standardized, manual handling assessment chart, snook table, one-dimensional cutting optimizer, and mistake proofing. As a result, a significant reduction in the overall cost of coils shops production processes were obtained. For instance, the average machines set up time was reduced by 18 %, number of set up per shift was reduced by 20.8 %, the number of operators was reduced by 26.3 %, the quality of the product was increased and the safety of the processes was enhanced. It is worthy to note the amount of the scrap was dropped by approximately 71 %.

A Lean Green Implementation Evaluation Method Based on Fuzzy Analytic Net Process and Fuzzy Complex Proportional Assessment

For the issue that the optimal selection of lean green implementation tools for performance effect, a method combining fuzzy analytic net process (FANP) with fuzzy complex proportional assessment (COPRAS) is proposed. Firstly, the main properties of the lean green performance and candidate tools are determined based on the production requirements and expert knowledge. Then, the fuzzy comparison matrix of each attribute is constructed according to the expert judgment represented by triangular fuzzy number, and the FANP method is used to obtain the importance weight of each attribute. After that, the fuzzy decision matrix between attributes with tools alternatives is constructed, and multiplying it with the attribute weight so as to obtain the weighted normalized decision matrix. Finally, the fuzzy COPRAS method is used to analyze the decision matrix to get the utility of each tools alternative. Based on the model and analysis, these results make us understand and be familiar with the most influential practice tools on performance benefits. These findings are expected to policy makers and industrial practitioners to focus on key elements of the success of the manufacturing business to facilitate both lean and green manufacturing implementation and assessment, and contribute to sustainable growth.

Development of Lean Manufacturing Implementation Framework in Machinery and Equipment SMEs

Development of Lean Manufacturing Implementation Framework in Machinery and Equipment SMEs

Lean Manufacturing Implementation To Reduce Waste On Weighing Scale Assembly Line

Lean Manufacturing Implementation To Reduce Waste On Weighing Scale Assembly Line

Lean Manufacturing and Environmental Sustainability: The Effects of Employee Involvement, Stakeholder Pressure and ISO 14001

This paper explores the relationships between lean manufacturing (LM), the promotion of green practices, employee involvement, pressure to take actions against environmental issues, the adoption of an ISO 14001-based environmental management system (EMS) and environmental performance in order to understand how LM can help improve environmental performance through environmental practices and the development of a lean culture. The effects of pressure to “go green”, employee involvement and the adoption of an EMS based on the International Organization for Standardization’s standard ISO 14001 are discussed. Data were collected from 220 Chinese manufacturing firms and analyzed using partial least squares (PLS) regression. The results suggest that the implementation of LM has a positive effect on the promotion of green practices and consequent achievement of high environmental performance; employee involvement is a moderator that affects the relationship between green practices and environmental performance; pressure to “go green” is a mediator in the relationship between LM and green practices; however, the adoption of ISO 14001 does not act as a moderator on the relationship between LM and green practices, but synergies emerge if ISO 14001 is integrated with LM. The study shows the importance of human attitudes and fosters managers to develop the necessary mechanisms to ensure and enhance employee involvement and lean culture. Although these determinants of environmental sustainability have been studied separately until now, this paper analyzes them simultaneously, investigating the relationship between different strategies and shedding some light on successful actions that promote sustainable manufacturing, and on the role of LM in sustainability. The findings can help manufacturers to take the initiative to improve environmental performance and assist governments in implementing industrial policies.

The complementary effect of lean manufacturing and digitalisation on operational performance

The most recent trend manufacturers have embraced to seek operational performance improvements is the use of a wide range of digital technologies typically associated with Industry 4.0. However, few studies have investigated the relationship between such technologies and the long-established lean manufacturing domain, and how they, together, influence operational performance. Based on data from a cross-sectional survey of manufacturing companies, this study investigates the relationships between the use of lean manufacturing, factory digitalisation, and operational performance using hierarchical multiple regression analysis. While simultaneously controlling for the effects of production repetitiveness, company size, and length of lean manufacturing implementation, the findings show that both lean manufacturing and factory digitalisation individually contribute to improved operational performance. Furthermore, it is found that when used together, they have a complementary (or synergistic) effect that is greater than their individual effects combined. These research findings provide both theoretical and practical insights into how lean manufacturing and factory digitalisation affect the operational performance of manufacturing firms. In light of the upcoming fourth industrial revolution, these findings suggest that lean manufacturing is not obsolete but rather is more important than ever in order to reap the benefits from emerging technologies and translate them into improved operational performance.

Implementation of Lean Manufacturing and Kaizen to Improve Productivity in The Production Floor

Currently the industry is trying to improve its competitiveness. This makes the manufacturingindustry needs to adapt the Lean-Kaizen concept. Lean-Kaizen means eliminating waste through small improvements made on an ongoing basis. This research takes a case study at PT Inoac Poltechno Indonesia, which is engaged in foam production. The current production target is only 56% of the planned target. Besides that, there are found many defective products and activities that have no added value. Furthermore, a map of the current condition is made to find waste and know the kaizen that will be carried out. Furthermore, a future map was developed with work standardization and Value Stream Mapping to determine activities that have no added value. Calculation of Waste Assessment Model (WAM), shows the biggest waste is defect (26.73%), inventory (15.79%), and waiting (13.35%). This study found that by adding trolley, adding operators, making SOPs, scheduling engine maintenance would make non-value added (NVA) activities decrease from 29.95% to 20.5%. Process Cycle Efficiency increased from 22.31% to 28.25% (thus fulfilling international PCE requirements for the manufacturing industry). Keyword : Lean-Kaizen, productivity, waste

Analysing the influence of organisational culture and leadership styles on the implementation of lean manufacturing

This paper aims at identifying the combination of organisational culture profiles and leadership styles that best support companies implementing lean manufacturing practices. For that, 225 leaders from manufacturing companies at various stages of lean implementation were surveyed. The analytical approach clustered respondents and their respective firms according to prevailing organisational culture, leadership style and level of implementation of lean practices, testing for frequency differences among clusters. This study states that organisational culture profiles are related to leadership styles and lean manufacturing implementation level, suggesting different-from-expected effects of this relationship on lean manufacturing implementation. The study bridges a gap in the literature by exploring how the association between organisational culture and leadership styles occurs in companies that are adopting lean practices.

Implementation of lean manufacturing to enhance the efficiency of acrylic resins production process

High lead time processing of acrylic resins leads to the production of products to consumer undergoes and high-production costs. This study aims to reduce lead time by analyzing various activities that have value-added, non-value-added, and necessary non-value-added. The research is conducted using lean manufacturing approaches on acrylic resin production processes. The analysis shows that the activity of delay and transportation is a contributor of waste that occurs in the production process of acrylic resins. Improvements by minimizing both activities in the are thining tank, reactor, and monomer tank can increase the efficiency of the production process. The improvement results show a decrease in lead time from 1298 minutes to 1075 minutes. This study demonstrates that lean manufacturing can improve the time process efficiency of 17.18%, which means the output ratio will increase by around 17.18% in a process.

Lean Manufacturing Implementation on Extrude Process with Value Stream Maping: Study Case in Tyre Manufacture

Lean Manufacturing has been known by all industries as one of the strategic tools adopted to compete in the tight market competition recently. This research will be focus on implementation of lean manufacturing at the one of the biggest local tire manufactures located in Tangerang which had a problem of production achievement was 92% to the schedule planned and the main caused by shortage building due to waiting material from preparation department. Value Stream Mapping (VSM) will be used to identify the waste at extruder since 55% problems was came from extruder. The method approach by started of identifying VSM current state, Gap analysis and action plan, and the last step is identify VSM future state and review the result. From VSM Future state, its resulted the reduction of lead time process extruder from 13.72 minutes/batch to 12.8 minutes/batch and WIP stock can be reduced from 12, 8 hours to 10.6 hours. Finally the shortage at building has been reduce from 7% to 3.2% and OEE building is increasing from 61% to 64.8%.

Waste reduction by implementation of CNC machining center and Lean Manufacturing

In the context of increasing competitiveness, the companies from manufacturing industry are constrained to provide quality products at a lower price and a shorter delivery time. This brings new challenges during the manufacturing process. One of the main challenges is to reduce or eliminate waste during the production stage. The actual paper presents methods and solutions through which the waste from the manufacturing process is identified and eliminated. As a consequence, increased productive efficiency and higher profit have been gained. The objective of this study is to implement Lean manufacturing tools, in order to improve the production process carried out within a manufacturing company, with a small manufacturing batch. Based on real data from the manufacturing process, the current value stream mapping (VSM) was built, identifying both operational and non-operational times. After waste identification, an optimal solution was chosen for the manufactured parts required by the customer. Implementing the best solution resulted in a productive efficiency increase by 90.93%, which significantly reduces the manufacturing time.

Waste reduction by implementation of CNC machining center and Lean Manufacturing

Waste reduction by implementation of CNC machining center and Lean Manufacturing

Practical implications and future research agenda of lean manufacturing: a systematic literature review

Academic literature on Lean Manufacturing (LM) is widely available. However, due to its fragmentation, the contribution of LM from practical and academic perspectives is controversial. This paper establishes the practical implications of LM studies carried out worldwide and identifies novel research streams. A Systematic Literature Review (SLR) of peer-reviewed journal articles was conducted. A total of 403 articles published in 62 journals during 2010–2019 were collected from four major management science publishers. An ‘affinity diagram’ was applied to organise the data into natural and logical themes. Conceptual frameworks concerning LM practical implications and future research agenda were formulated. Meaningful themes of LM practical implications and future research suggestions were revealed and classified into two categories. In category one pertaining to the internal nature of LM, themes related to the pre-implementation, implementation and post-implementation phases of LM were identified. In category two pertaining to the external nature of LM, themes related to the country in which the companies operate, the diverse managerial systems available, and the methodological research approach were identified. The main themes supported in the literature by most references were determined. Finally, respective statements concerning the practical implications of LM and the future research agenda are analytically presented.

Lean bundles within Jordanian manufacturing SMEs and their effect on business performance

Maximizing customer value and minimizing waste have become the heart of the formulation of SMEs in the manufacturing sector of Jordan to survive in the new global marketplace. Therefore, lean manufacturing philosophy is used in SMEs to improve performance regarding quality, delivery, and costs to become efficiently competitive, thus accomplishing sustainable economic growth. The current study was designed to analyze the extent to which lean management bundles are adopted by SMEs manufacturing organizations in Jordan and the effect on their performance. Data were collected from 278 manufacturing SMEs in Jordan based on a structured questionnaire. The theoretical relationships were examined using structural equation modeling. The results show that Total Quality Management (TQM) and Human Resources Management (HRM) lean bundles are positively associated with manufacturing SMEs’ performance. The outcomes of this study may be considered as incentives for other practitioners and entrepreneurs of SMEs when implementing lean bundles by acknowledging the positive effect on their performance. Moreover, the findings of this study could be used in an internal checklist before and during the implementation of Lean Manufacturing (LM).

A Fuzzy VIKOR method to analyze the risks in lean manufacturing implementation

Lean manufacturing is a theory, widely identified to gain more profits, reduce waste, and deliver valued products for customers without harming productivity. Albeit, it is a lucrative business trick, but implementation possesses a massive hurdle for success in any organization. Therefore, for the successful implementation of a lean manufacturing system, the factors and the risks involved should be identified and eliminated. This research is a case study of such risks involved in the implementation of Lean Manufacturing system in medical equipment manufacturing firms located in the southern part of India. The identification of risks was made by a literature survey as well as inputs from industry experts and analysis of risk using MCDM methods like Fuzzy Nominal Group Method (NGM) and VIKOR (VIseKriterijumskaOptimizacija I KompromisnoResenje) methods. The outcome of this paper is a selection of the best medical equipment manufacturing firms among a list of firms, based on the implementation of a lean manufacturing system. The proposed outcome of this research work was verified with case companies, existing literature, and consultation with experts. Finally, a sensitivity analysis was used to validate the results from the above methods.

Synergistic effect of lean practices on lead time reduction: mediating role of manufacturing flexibility

PurposeThis study scrutinized the synergistic effects of lean manufacturing (LM) on lead time reduction (LR) while investigating the mediating role of manufacturing flexibility (MF) in that relationship within the context of batch and mass customization manufacturers.Design/methodology/approachThis cross-sectional survey involved 160 large batch and mass customization manufacturers in Indonesia. Data were analyzed by using the PLS path modeling approach and multigroup analysis.FindingsThe positive synergistic direct effects of LM on LR and MF were revealed in both process types. In mass customization, MF mediates the effect of LM on LR. However, such a mediating effect was not found in the batch process due to the insignificant effect of MF on LR.Practical implicationsThe findings offered theoretical and practical insights supporting the manufacturers to grasp potential benefits through the holistic LM implementation as well as the suitable strategies to improve MF and reduce lead time by considering the types of the production process.Originality/valueThis study bridged the gaps regarding the comparison of LM implementation and its influence on MF and LR in mass customization and batch production.

Enablers of Target Cost Management Implementation: Evidence from Malaysia

This study used contingency theory to examine the key enablers of target cost management (TCM) at the Malaysian context. Using a single case study approach, a questionnaire survey was conducted on users of TCM at Company A, a Malaysian automotive company. The respondents were required to determine whether enablers, namely, an advanced manufacturing technology (AMT) implementation, confrontational strategy, customer orientation, an information-sharing network, lean manufacturing implementation, supplier relationships, teamwork oriented organizational culture, top management support and commitment, and training havepositive relationships with the successful implementation of TCM. The findings show that only teamwork, top management support and commitment, and training are the key enablers for the successful implementation of TCM in the case company.

Lean manufacturing implementation in time of crisis: the case of Estaleiro Atlântico Sul

The implementation of Lean Manufacturing (LM) philosophies in the 1980s and 1990s revolutionized manufacturing in high volume flow-oriented production processes. In project-oriented industries such as shipbuilding, long lead times, lumpy demand, and dependence on external and often international suppliers have made LM implementation challenging. This paper analyzes lean manufacturing implementation at Estaleiro Atlântico Sul (EAS) a shipyard located in an underdeveloped region in northeastern Brazil. EAS was the recipient of multiple oil tanker contracts from the Brazilian oil company Petrobras, but was unable to meet delivery deadlines and suffered cost overruns until a strong LM culture was introduced. From the EAS case, we make suggestions for a more appropriate lean manufacturing implementation in an emerging economy context. This is especially relevant in those situations associated with special project types of manufacturing initiatives such as shipbuilding, aviation, construction projects and other forms of low volume high complexity and other long-lead time production operations.

Implementation Selected Tools of Lean Manufacturing

This study aims to understand the general perspective of industrial company operating in Sabah, regarding the implementation selected tools of lean manufacturing. The objectives of this paper are to evaluate the implementation of lean manufacturing and its tools among manufacturing company located in Sabah. Apart from that, it will also identify the problem and factor in implementing lean manufacturing tool as well as the benefits experienced after the adoption of lean manufacturing tools. The scope covers manufacturing company of any types of industry that is actively operating in Sabah, regardless of size. Instrument of study is a survey questionnaire that contains open and closed ended questions, sent out to target respondents. Data analysis is done using descriptive statistics to explain the trends in dataset and Cronbach’s Alpha to test the internal reliability of the instrument. This study finds significant evident of the implementation of lean manufacturing and its tools among manufacturing companies in Sabah, as well as the problem faced in implementation, factors of implementation and benefits experienced after the adoption of lean manufacturing tools.