Lean Manufacturing Philosophy Research Articles

Losses VS Opportunities: Principles of Lean Management in the Academic Field

Currently, the concept of lean management is increasingly becoming the focus not only of representatives of the production sector, but also of educational and scientific organizations, healthcare organizations, government and regional authorities, etc. In this article, the authors show that the implementation of lean management principles and tools in the activities of academic organizations allows you to “restart” many processes and reduce the loss of quality and productivity by several times without significant costs. The first part of the article describes the main stages of the formation of the lean management concept and the contribution of Russian scientists (A.K. Gastev, I.V. Rebelsky (the basics of lean mental labor)) to the development of both methodological and practical recommendations that currently constitute the core of the philosophy of lean manufacturing and management. The central place in the article is devoted to the features and classification of losses in relation to both the activities of the organization as a whole and the activities of scientific and pedagogical workers (along with the “classical” classification of losses developed by T. Ono and J. Liker, ten features were emphasized to identify losses in the academic field). Among the reasons that led to an increasing interest in the use of lean management technologies in the academic field, the authors highlight the following ones: strengthening management and formalization in assessing performance indicators, strengthening information asymmetry, changing the level and quality of communication of employees, updating the problem of precarization of scientific and pedagogical workers’ employment and gradual blurring of the boundaries between work and rest. In the final part of the article, a set of recommendations was formed to identify losses in the activities of scientific and pedagogical workers, and an algorithm for their elimination was proposed.

Framework for Lean Implementation Through Fuzzy AHP-COPRAS Integrated Approach

Manufacturing industries strive hard to improve their productivity to meet the highly demanding business market. Productivity can be improved by effective use of resources, elimination of wastes, process flow enhancement, and continuous improvement. There are strategies and tools to improve productivity but industries face the problem of selecting appropriate strategies. Lean manufacturing philosophy helps the manufacturing industries to enhance their productivity aspects by identifying and eliminating the wastes using specific tools/techniques. This article presents an integrated framework for the lean implementation process in the steel processing industry. The value stream mapping (VSM) tool is used to identify the wastes at each stage of the production process. Lean tools are identified from literature based on the wastes identified from the current state. For prioritizing the lean tools based on the positive correlation on one another, fuzzy integrated analytic hierarchy process and complex proportional assessment of alternatives are used. A future state value stream map is developed to illustrate the improvements achieved due to the implementation of selected lean tools. Comparison of present and future state VSM shows a great reduction of wastes, such as scale waste (50%), miss roll defects (72.7%), size variation defect (62%), corrosion defect, and improvements in talk time and cleanliness.

Analysis of the impact of the 5S tool and Standardization on the duration of the production process - case study

Abstract The high level of competition in the manufacturing industry requires the creation of working conditions that allow for the efficient implementation of production processes. One of the solutions enabling the adaptation of production stations to improve the work performed by employees is the implementation of a management system based on the Lean Manufacturing (LM) philosophy. The purpose of this article was to determine the potential impact of the implemented LM tools, in the form of 5S and standardization, on the efficiency of the production process in specific production conditions. The methodology of the conducted research included: obtaining data before and after the implementation of LM tools (in total 12 months). The data was used to determine the effectiveness of individual operations, and then to conduct a comparative analysis using statistical tests. It was found, among others, that the implementation of LM tools resulted in an increase in the efficiency of the manufacturing process by about 11 percentage points. The obtained results confirm the thesis that a manufacturing company, in order to maintain its position on a competitive market, can improve the efficiency of processes by using tools such as LM. The selection of tools must be adequate to the implemented processes, so that they bring measurable increase in efficiency.

Applying lean principles to innovation management

The innovative potential of the organization is increasingly becoming one of the key factors of competitive advantage. The philosophy of lean manufacturing has a well-established reputation for its focus on process efficiency and is therefore often applied in various areas of innovation. This broad and growing applicability has resulted in a large body of literature on lean innovation. The purpose of this article is to conceptualize an integrative view of Lean Innovation Management. Based on a systematic review of the literature, key principles and practices of lean manufacturing that are useful in the context of innovation management are identified and combined into a comprehensive framework. Five aspects of lean innovation are identified: coaching, learning culture, collaborative organizational structure, collaborative external networks and learning procedures), which reflect the structure of the relationship between lean manufacturing and innovation. Contributing to the current socio-technical concept of lean, this study brings together the literature into a comprehensive framework of cultural, relational, organizational, technical, and leadership qualities. Future research may focus on the Lean Innovation Management transformation process and how it can be monitored and evaluated according to management maturity levels or organization development stages.

Application of Lean Manufacturing Philosophy to Improve Occupational Safety Results in a Mining Company

Application of Lean Manufacturing Philosophy to Improve Occupational Safety Results in a Mining Company

Analysis of Implementation of an AGV in Agribusiness Company

Objective: This paper presents a case study, in a large agricultural machinery assembler, where a method is proposed to ensure an analysis, implementation and validation of the implementation of AGVs in the agribusiness industry. Theoretical framework: The use of AGVs in the agribusiness industry provides several operational benefits, which are reflected in the optimization of its processes. Thus, becoming more competitive, reconciling new trends and market demands, providing margins of error and increasingly narrow quality standards. Improvement of product quality: When it comes to car dealerships and their after-sales services, customer satisfaction and/or complaints, there is a scarcity in the literature that reinforce the use of the process mining technique. Thus, to cover this gap, there is a clear need for this research. Methodology/approach: Using practices from the Lean Manufacturing philosophy, strategies were defined on how to reduce these losses, replacing idle labor with autonomous vehicles. Results: Results demonstrate significant gains in a low payback time of 45 days and a 22% reduction in operating costs. Research, practical and social implications: Based on the studies presented in this document, it is possible to verify a considerable loss of labor, due to operator idleness and its resources, such as the transporter cart, as well as layout restrictions and supply models. Originality: Industry 4.0, also called the Fourth Industrial Revolution, brings technologies to the manufacturing environment. One of them is the use of self-guided vehicles - AGV - to ensure greater agility, dynamism and organization in the operation in an industrial environment.

Can Industry 4.0 Assist Lean Manufacturing in Attaining Sustainability over Time? Evidence from the US Organizations

Recent research asserts that Industry 4.0 technologies have positively impacted Lean Manufacturing and sustainable performance. Although the combined impact of Industry 4.0 and Lean Manufacturing on sustainable performance has been scientifically studied, no study has shown how Lean duration moderates the relationship between Industry 4.0 and Lean Manufacturing in US manufacturing firms. This research aims to close this gap by evaluating whether Lean duration moderates the association between Industry 4.0 and Lean Manufacturing, which in turn affects sustainability performance. The Structural Equation Modeling (SEM) method was used to formulate and examine proposed relationships. The study used data collected from 126 managers who worked in 65 different manufacturing organizations. The data demonstrated a moderating effect of Lean duration on the relationship between Industry 4.0 and Lean Manufacturing and a significant and direct effect of Lean Manufacturing on sustainable performance. However, Industry 4.0 had a positive indirect effect on sustainable performance through the moderating effect of Lean Manufacturing and a negative direct impact on sustainable performance. The study’s findings add to the body of knowledge on the impact of Industry 4.0 on the Lean Manufacturing philosophy by identifying Lean duration as a moderator of this relationship. Theoretically, this research empirically validated the association between Lean duration, Industry 4.0, Lean Manufacturing, and sustainable performance in US Manufacturing organizations. The results showed that industry practitioners should consider the effect of Lean duration when adopting and managing Industry 4.0 technologies for better sustainable performance.

The Determinants of Digital Transformation in Lean Production Systems: A Survey

Due to continuously changing conditions (Covid-19 pandemic, energy crisis) the companies search for ways to change their business model and structure in order to remain competitive by utilizing lean manufacturing philosophy and industry 4.0 technologies. The digitalization process is inextricably linked with the introduction of industry 4.0 technologies. In the industry 4.0 era, the systems collect information and data from multiple sensors and adjust the function of the production process without human intervention offering flexibility and automation. Digitalization entails the development of digital organization units with smart devices enabling human-to-machine communication emerging as a key factor. The aim of this paper is to present the framework and the successful strategy for the digital transition of industries combining lean manufacturing principles. To achieve this target, a survey was applied to identify the trends of businesses and investigate the relationship with lean production techniques. Additionally, a logistic regression model is developed based on the survey data. The present paper presents the crucial factors, the most significant obstacles to digital transformation and the most widespread industry 4.0 technology.

High Performance Work Systems: An Interactive Variable of the Relationship Between The Characteristics of the Reconfigurable Manufacturing System and the Philosophy of Lean Manufacturing

The current research seeks to present a perception of the role of high performance work systems in achieving the relationship between the reconfigurable manufacturing system and the philosophy of lean manufacturing, and on this basis a hypothetical scheme was built that reflects the nature of the relationship between the research variables, The independent variable is represented by the reconfigurable manufacturing system, The dependent variable is represented by the Lean Manufacturing philosophy, while the interactive variable is represented by the high performance work systems, The research included a theoretical framework for its variables in light of a group of Arab and foreign sources related to its subject, The research also adopted a field framework to measure the nature of the relationship and the impact between the research variables, based on a questionnaire prepared for this purpose, The researchers chose the General Company for the Automotive Industry and Equipment / Babylon Battery Factory as a field for the current research, As for the research sample, it was represented by a sample of them that included (220) individuals from its administrative leadership and specialized technicians holding a bachelor’s degree, In light of the answers provided by the respondents, which were analyzed using the statistical software (SPSS V23), (AMOS 24), it was confirmed that there are direct and indirect correlations and effects between the research variable, On the basis of this, the research reached a set of conclusions indicating the presence of direct and indirect effects of the reconfigurable manufacturing system and high performance work systems in the Lean Manufacturing philosophy, A set of proposals was presented indicating the need for the manufacturing system in the factory

Application of lean education as a way for the elimination wastes in an automotive manufacturing process: A case study in a company of stamped products sector of Manus Industrial Pole / Aplicação da educação magra como forma de eliminação de resíduos num processo de fabrico de automóveis: Um estudo de caso numa empresa do sector de produtos estampados do Pólo

The present work was carried out in a company in the sector of Metal Imprints that provides parts for automakers of the Two Wheels Sector that needed to improve the productivity of the process of stamping and welding. It intends to present the process of development of the professionals of a company of printed products, from the application of tools associated with the philosophy of lean manufacturing, aiming to carry out activities that reduce the waste in the production process. For this, the methodology used was a case study, in addition to bibliographical research on the themes of lean manufacturing and lean education. The main results achieved were the absorption of the knowledge obtained that enabled the generation of activities that contributed to the reduction of wastes within the analyzed processes. In the end, we can conclude that for companies to remain competitive in the market, they must invest more and more in human capital. In this sense, lean education is a very viable alternative for reaching the goals and objectives of organizations.

Evaluating the performance of a cellular manufacturing system proposal for the sewing department of a sportswear manufacturing company: A simulation approach

Cellular manufacturing systems (CMS) are a major application of group technology, that brings benefits related to the reduction of wastes, also known as ‘mudas’ in lean manufacturing philosophy, to organisations striving to compete on today’s markets. These benefits include the reduction of machine setup times, material handling and work-in-process inventory, among others. However, many organisations are reluctant to implement such decisions in their production systems, due to the uncertainty and economic and productive impact that these involve. For this reason, a simulation study is performed in this paper to evaluate the performance of a cellular manufacturing system approach for the sewing department of a sportswear manufacturing company. The simulation study was designed, and the results of the proposed model showed improvements of 51,46% in the average flow time, 1102,52% in the average throughput, and 50,65% in the average setup times of machines, compared to the current state of the case study.

The tasks of using artificial intelligence in lean manufacturing

Modern conditions of functioning of industrial enterprises associated with a high degree of market competitiveness, market conditions, necessitate the improvement of production process management in order to optimize production, reduce production losses and increase labor productivity. The prompt and effective solution of these tasks is possible through the use of artificial intelligence, which allows not only to collect, analyze and structure production information, but also to increase the effectiveness of people’s work, improve the quality of manufactured products, and increase the efficiency of the enterprise as a whole. In turn, the implementation of the lean manufacturing concept at the enterprise can be carried out with great success with the widespread use of artificial intelligence technologies. The purpose of this article is to determine the range of tasks that can be solved using artificial intelligence in the implementation of the principles of thrift. At the same time, artificial intelligence is considered as an additional tool in the tool kit of lean manufacturing, enhancing the resulting effect. As a result of the study, the tasks to which artificial intelligence technologies are involved in the framework of the well-known lean production tools are identified. The article notes that the idea of continuous improvement occupies a central place in the philosophy of lean manufacturing. It is about focusing on constant change. Readiness for changes in the enterprise should be maintained constantly, so that when there is an opportunity for improvement, appropriate measures can be implemented. This possibility can be determined in a timely manner using AI tools. According to the results of the study, it was concluded that artificial intelligence technologies, regardless of their size and the production technologies used, incorporated into the processes of thrift, allow to obtain a synergistic effect that affects the functioning of the entire enterprise.

Design of lean-based strategies to improve the flow of materials in the value chain of a furniture company in Colombia

This study aims to analyze the general process conditions in a furniture company in Colombia. Many improvement opportunities were identified and addressed using lean manufacturing tools and philosophy to increase the process's outcome. The methodology allowed some activities to reorganize and identify deficiencies in personnel formation, housekeeping, lack of tools, and other factors affecting the process. Different actions were implemented with the commitment of directives, operators, production management, and other areas. The discipline showed for all the problematic areas allowed to increase the outcome of the process by 21%.

Lean and industry 4.0: A leading harmony

Avoid waste, get rid of non-value-added operations, keep processes and equipment simple and easy to maintain, these are the major assets of the Lean Manufacturing philosophy of the Toyota Production System (TPS). If Industry 4.0 offers a whole new way of considering decision-making in terms of problem solving, Lean Manufacturing multiplies the opportunities to integrate into continuous improvement. Digitalization being the trend of this new era where everything is connected, a new version of Lean has emerged: Lean 4.0. It is a combination of Industry 4.0 technologies and Lean Manufacturing principles that allows the benefits of these two paradigms to be fully exploited. The objective of this article is therefore to present what Lean Manufacturing is and how it has adapted to new technologies to make way for Lean 4.0. It constitutes a literature review based on some authors statements regarding this new concept, and a reflection paper proposing some practical cases of Lean 4.0 concretized by a simulation based on the case study that shows time and productivity gains within a Moroccan company, serving as an example to demonstrate the power of Lean 4.0.

Application of Lean Manufacturing Concepts to Evolving a Policy for Engineering Education

This work analyzes the current situation of engineering education in India, especially technical universities characterized by low-quality infrastructure, inflexible curricula, and poor teaching resources including faculty, usually resulting in low student learning and very low graduate placement rates, and identifies the root causes of these problems, summarizes the methodologies adapted by previous researchers in the lean area, and applies the lean manufacturing philosophy to engineering education. This paper applies a value stream map to analyze the current state of engineering education. This technique identifies eight wastes and is given in form of a current state diagram. A future state diagram is presented that recommends solutions to eliminate these wastes. These recommendations make learning processes responsive to needs and provide long-lasting value to students. Overall, it is beneficial in developing a policy for engineering education.

The Concept of Lean Manufacturing as a Tool for Improving the Process of Education

Aim. The presented study aims to examine approaches to organizing the educational process in the system of general education in accordance with the basic principles of lean philosophy, better known in Russia as “lean manufacturing philosophy”, which has proven to be an effective tool for building business processes in industrial enterprises.Tasks. The authors determine the value created by applying the principles of lean education in the general education system, describing the value creation flow and its customer; examine the classification of losses in the value stream and identify losses in the educational process based on national standards for lean manufacturing and quality management systems; apply the described system to the educational process of Gorchakov MGIMO Lyceum.Methods. This study uses empirical (observation, measurement) and theoretical (abstraction, formalization, and modeling) research methods, as well as methods of grouping, comparative, structural, and functional analysis.Results. The study substantiates the authors’ hypothesis that the analysis of the educational process through the definition of value for the consumer/customer and the identification of different types of losses transforms the value creation flow into the “lean education” flow, which perfectly meets the needs of stakeholders. The maps of the current and future state of the value creation flow of the educational process of Gorchakov MGIMO Lyceum are modeled. A comparative classification of the types of losses in the manufacturing and educational processes is created. The results of testing the hypothesis in the educational process of the specified lyceum are presented.Conclusions. Application of lean philosophy (the concept of lean manufacturing) can improve various activities, including education. The study provides evidence for this by defining and constructing the value creation flow in accordance with the requests of all stakeholders in the educational process and also by identifying losses in the methods and processes of information transfer and further evaluation of the knowledge and skills of students.

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

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

BARRIERS TO IMPLEMENTATION OF LEAN CONSTRUCTION TECHNIQUES IN GUJARAT CONSTRUCTION INDUSTRY

Lean construction technique has been arisen from endeavouring and applying Japanese lean manufacturing philosophy to the construction industry. Large research is being done recently and an ongoing process to adopt lean principles to the construction industry to enhance the efficacy, amelioration of waste. The success of the lean technique is evident, but some major reports indicated that major challenges are related to the Mis-conceptualisation of lean thinking, and some case studies have ascertained that the lean technique was either applied partially or erroneously. The purpose of this paper is to elucidate the lean concept, wastes in construction, features of lean project delivery, lean principles and the barriers to implementing the lean technique in the Gujarat construction industry. A compendious review of the literature had been done with the perspective of reaping pertinent data needed for the paper and to make a questionnaire. To check the reliability of data Cronbach’s alpha was used. Followed by a statistical analysis of data by Relative Important Index (RII) and ranks were given. Further analysis discovered that only nine of these barriers were determined significant, where dominant factor was Resistance to change and culture with an RII value of 0.63. The results of this study could be used to help researchers, practitioners and companies in the Gujarat construction industry to fasten their attention on the suggestive issues to the prosperous implementation of the lean concept. Lean construction technique has been arisen from endeavouring and applying Japanese lean manufacturing philosophy to the construction industry. Large research is being done recently and an ongoing process to adopt lean principles to the construction industry to enhance the efficacy, amelioration of waste. The success of the lean technique is evident, but some major reports indicated that major challenges are related to the Mis-conceptualisation of lean thinking, and some case studies have ascertained that the lean technique was either applied partially or erroneously. The purpose of this paper is to elucidate the lean concept, wastes in construction, features of lean project delivery, lean principles and the barriers to implementing the lean technique in the Gujarat construction industry. A compendious review of the literature had been done with the perspective of reaping pertinent data needed for the paper and to make a questionnaire. To check the reliability of data Cronbach’s alpha was used. Followed by a statistical analysis of data by Relative Important Index (RII) and ranks were given. Further analysis discovered that only nine of these barriers were determined significant, where dominant factor was Resistance to change and culture with an RII value of 0.63. The results of this study could be used to help researchers, practitioners and companies in the Gujarat construction industry to fasten their attention on the suggestive issues to the prosperous implementation of the lean concept.

Lean practices and operational performance: the role of organizational culture

PurposeThere is a scarcity of research about cultural aspects of organization related to lean implementation. The purpose of this research is to investigate the effects of lean practices and organizational culture on the operational performance of small- and medium-sized manufacturing enterprises.Design/methodology/approachThe study is based on a survey conducted and data collected from 215 manufacturing SMEs in India. The hypothesized relationships are then analyzed with structural equation modeling.FindingsThe results showed that the constructs of lean practices and organizational culture have significant and direct effects on the operational performance of Indian manufacturing SMEs. Further, this research shows the mediating effect of organizational culture on sustaining lean processes within small-medium manufacturing business setups.Research limitations/implicationsFuture research is required in a more diverse context to confirm the generalization of the results. Future research may be extended to investigate the effects of lean and organization cultural aspects on measures of financial, social and environmental performance.Practical implicationsThe results obtained would help managers of manufacturing SMEs to better understand the linkage between lean and operational performance, considering the aspect of cultural change management in an organization. The outcome of this research provides useful indications of how organizations can work to sustain the philosophy of lean manufacturing within their workplace.Originality/valueThere is a lack of research at the critical intersection of organizational culture and sustainability of lean implementation. Culture is key to making changes required for lean implementation and in sustaining the drive toward lean production and management. This research is an attempt to fill that gap.

Applications of Lean Tools for Compressor Assembly Line

In last decades, competition between several industries to deliver high quality products is marginally increasing in terms of costs and performance. Lean manufacturing is one of those activities, which focus on the reduction of cost by eliminating non value adding activities. The general idea behind Lean manufacturing is to eliminate non value adding activities which again leads to eliminate waste. Higher flexibility, better quality and effective production system the manufacturer requires new ideas on production line. All the Lean tools are used to implement newer ideas into production line which improves the overall production process. This Paper addresses the application of lean manufacturing philosophy to the compressor assembly line of a well-known industry. In this paper, Failure Mode Effective Analysis, Value Stream Analysis and Takt time are the lean tools effectively integrated resulting in the improvement in terms of cycle time, space available, distance travelled by worker and productivity which leads to delivering the customer demand within time.