Lean Manufacturing Techniques Research Articles

Design of an improved layout for a steel processing facility using SLP and lean Manufacturing techniques

AbstractImplementing lean manufacturing practices in the systematic layout planning (SLP) process for improving facility layouts in various industries is essential. This approach enhances material handling processes and effectively manages space utilization. An efficient plant employing systematic layout planning leads to improved resource utilization and facilitates the integration of lean manufacturing techniques such as value stream mapping, 5 S, Ohno’s 7 wastes, and cellular manufacturing. This research article presents a case study on a steel processing plant in Dubai with an area of 160 m × 160 m, where systematic layout planning and lean manufacturing techniques were applied. The factors considered included space and material flow optimization, incorporating layout alternatives based on systematic layout planning principles along with lean manufacturing techniques. The study revealed a 34% reduction in material flow and an efficient overall space utilization improvement of 26%. Additionally, cost analysis validation was conducted.

Managing Operations and Supply Chains in Automotive Industry

Profitability, customer satisfaction, and innovation in the cutthroat automobile industry depend on well-managed operations and supply networks. Managing operations and supply chains in the automotive industry is complex, and this paper lays forth a comprehensive framework for doing so. An integral part of effective operations management in the automotive industry is demand forecasting and planning. Using collaborative forecasting methodologies, market trend analysis, and advanced analytics, automotive manufacturers can improve production schedules, minimize inventory costs, and foresee changes in demand. Reducing waste, enhancing process efficiency, and managing low inventory levels are all achieved through the use of lean manufacturing techniques like Just-in-Time (JIT) production and Total Productive Maintenance (TPM). Collaboration with suppliers, uninterrupted material flow, and supply chain innovation can all be achieved through supplier relationship management (SRM). Automakers may enhance product quality, cut costs, and lessen supply chain risks by communicating openly, working together to improve processes, and forming agreements that benefit all parties involved. Automobile companies can't afford to have any product flaws that damage their reputation or the loyalty of their customers, which is why quality management is so important in this industry. Statistical Process Control (SPC), Failure Mode and Effects Analysis (FMEA), and Six Sigma are a few of the rigorous quality control methods that manufacturers use to find and rectify flaws early

From Value Stream Mapping to Choreographic Tension Mapping: Preliminary Results and Insights from an Exploratory Study

ABSTRACT Value Stream Mapping (VSM), a lean manufacturing technique, is a process analysis approach that focuses on value and waste. This project explored the development and incorporation of a VSM-inspired tool to help dance composition students consider the value present in their choreography explicitly. The proposed Choreographic Tension Mapping (CTM) tool was incorporated into an upper-level dance composition course in the Dance Program in collaboration with the Department of Industrial and Systems Engineering at the University of Florida. Students used this tool multiple times throughout the semester. They responded to a set of prompts to reflect on their experience of using CTM and its impact on their creative processes. Students’ responses to one of the prompts were qualitatively analyzed. The preliminary findings demonstrated the potential benefits of the use of CTM to support the development of skills in choreographing, collaborating in a group, and giving constructive feedback in dance composition education.

Process Analysis and Modelling of Operator Performance in Classical and Digitalized Assembly Workstations

Strong competition in the automotive industry has required manufacturers to implement lean production, both with methods and techniques specific to Industry 4.0. At the same time, universities must provide graduates with specific skills for applying these new production methods and techniques. In this context, a lean learning factory was developed in the Pitesti University Center that allows students to learn about, experiment with, and research new lean manufacturing methods and techniques as well as Industry 4.0 in an environment similar to that of enterprises. The research presented in this study aimed to identify the minimum number of repetitions necessary to train operators to perform the same assembly operation while working at two differently organized workstations: one classic and the other including digital techniques. Several indicators were considered in our analysis, such as the number of errors, the number of stops, the effective duration of the work cycle, and the percentage ratio between the standard duration of cyclical activities and the effective duration of the work cycle. The evolution of these indicators was mathematically modelled by regression functions, using the least squares method. The obtained results also highlight the usefulness of applying the DOJO method as a lean-manufacturing-specific learning technique and the efficiency of implementing digital techniques in work organization.

An Approach to Reduce Production Lead Time in the Valve Manufacturing Industry

Lean manufacturing aids improved productivity and product quality by identifying and eliminating waste. The present work aims to utilize Value Stream Mapping (VSM), a lean manufacturing technique to minimize the cycle time in the production of valves. A current state map is developed with available information gathered from the production unit, to identify the time-consuming factors like waiting time, improper inspection, and the lack of material and resources for manufacturing. Problem-solving techniques like 5s, JIT, KANBAN, and KAIZEN are used to reduce time-consuming activities. Value-Added and Non-value-added activities are identified through Current State Map. Activities such as placing a purchase order, drawing, assembling, testing, packaging, and shipping are Value-added activities. Non-Value-added activities are identified as rework, inspection, movement, waiting for the next process, and over-processing. The job waiting time between the next process is reduced by 70% using the future state map and the productivity is enhanced.

Implementation of Lean Manufacturing Methodology and Its Application: A Literature Review

This study aims to investigate and analyze several previous works of relevant literature on the Lean Manufacturing technique in international journals. The methodology used to review the previous studies was carried out through a survey based on descriptive, qualitative, and bibliographical surveys in International Journal with restriction to the period of publication from 2017 – 2022 published on databases and electronic journals in English with the scope to examine and analyze in-depth the extent to which literature used to discuss results in the selected papers of applying the Lean Manufacturing technique in several case studies. After conducting a survey, only thirty-three articles were found with the theme of the application of Lean Manufacturing and its technique in manufacturing companies. Twenty-one techniques/tools of Lean Manufacturing were found problem-solving for waste time elimination, reducing process cycle times, and implementing process improvement. It is concluded that the most used methodology in waste reduction is Value Stream Mapping.

A Review of Literature on Lean Manufacturing Tools and Implementation Based on Case Studies

This research focuses on reviewing the Lean Manufacturing (LM) implementation which is widely applied in the manufacture company to overcome or reduce waste. The aim of this article is to find out more about the influence on the industry sector. This research was developed by collecting research from indexed databanks of Scopus, Science direct, ResearchGate, etc. This review study is significant to identify the application of lean manufacturing in dealing with waste through implementation into several case studies. A total of 24 articles were selected, taking into account criteria such as keywords, article titles and publications of international publishers, which were selected through a systematic process. This study found that the application of lean manufacturing is a method that brings many advantages that work by minimizing losses and waste, and the Value Stream Mapping method is more often used as part of several Lean Manufacturing techniques to identify and analyze the occurrence of waste while providing solutions that lead to improvement. process and cost reduction.

Lean Optimization of Batch Production in an Aluminium Company

This work investigates the optimization of a batch type of production and operational management in an aluminium company using a lean manufacturing system. The operation and production system of the case study company runs in various sectors, which led to waste in the system, hindering the company's ability to meet customer demand. Through operational data analysis and questionnaires, the team identified the types of waste generated by the case study company. Lean manufacturing techniques such as eight deadly wastes, Heijunka, takt time, 5S approach, quality tool management, value stream mapping, Kaizen, Kaban, Gemba, and top and bottom-level involvement were employed to manage the waste. The findings reveal defects in inventory, transportation, waiting times, and untapped ideas of employees, all of which significantly impact the company's performance. This allows for daily production of small batches of aluminium alloys (AA3001, AA3105, and AA3110) without issues, supported by the principle of pull production. Additionally, the application of Takt time results in a significant reduction of production time, leading to improved efficiency. The study also highlights the high interaction effect of transportation, defects, and inventory wastes on various production lines, such as the bogie fitting line paint line, and anti-intrusion. Among the lean manufacturing tools, Kaban, standard work, and 5S are identified as the most frequently used. The research findings provide valuable insights for manufacturing industry leaders to spot the performance gaps and enhance the application of lean manufacturing practices.

Impact of Social Compliance on Conflict Management in the Readymade Garment Industry

In the global ready-made garment (RMG) market, there is intense competition. To combat ethical issues in the supply chain, vendors have created compliance regulatory standards. Suppliers must also monitor, enforce, and disclose compliance. Therefore, the global garment industry exerted pressure on suppliers from developing countries to implement a code of conduct (CoC) that emphasized social responsibility. The apparel industry has discovered that this Code of Conduct is a valuable instrument for monitoring the compliance activities of its suppliers. Compliance is essential to the prosperity of any RMG organization, according to studies. Studies indicate, however, that it fails in the apparel industry because purchasers may exert pressure on suppliers to prioritize cost savings over non-compliance. Also, demand places suppliers under unnecessary pressure. It cannot, therefore, be used in the fashion industry. Consequently, both positive and negative compliance studies inspired this study. This research is based on contingency theory. The findings of this study illuminate the significance of the connection between social compliance and labor instability in Bangladesh's RMG industry. This study also proposes that Bangladeshi textile companies should have normally utilized lean manufacturing techniques to increase output in accordance with new regulations, despite social compliance challenges. The data in this quantitative investigation were analyzed using Statistical Package for the Social Sciences (SPSS) and Partial Least Squares Structural Equation Modeling (PLS-SEM). Simple random sampling was used to acquire data from 384 employees using survey techniques.

Industry 4.0 technologies integration with lean production tools: a review

PurposeLean production has been proved to be a cost-effective and efficient means of production that reduces non-valve added activities. Industry 4.0 (I4.0) is a technology-driven platform that allows machines to interact with other systems through artificial intelligence, machine learning, industrial Internet of Things (IoT), etc. that improve the production system with flexibility, quality and customization throughout the whole value chain. New approaches to digitization of lean production have recently been emerged and they are transforming the industry and increasing productivity throughout the value chain. Through this article, an effort has been made to review the research published in this field.Design/methodology/approachThis paper reviews the literature published in various journals, the databases Web of science (WoS), ScienceDirect, Scopus, Emerald etc. were referred with a focus on lean concepts and tools and I4.0 technologies; it has been noticed that the integration of the lean tools with I4.0 technologies is a very effective tool for the industry.FindingsIt has been found in the literature published earlier in various journals that lean manufacturing (LM) is commonly acknowledged and considered a best practice to improve the productivity. It is concerned with the tight integration of people into the industrial process through continuous improvement which leads to value addition throughout the whole value chain by eliminating non vale added activities. The findings show that organizations can improve their productivity and flexibility with speed and accuracy by integrating I4.0 technologies with LM, which is foremost need of any industry across the world.Originality/valueThis article accentuates the connections between the principles and tools developed under the umbrella of I4.0 and those developed by the LM techniques, with a specific emphasis on how some of the principles and tools of I4.0 improve the implementation of lean principles dependent on the competence levels of the technology. Very few articles have been published in this area, and this paper is an original piece of research covering a review of extant research published in various journals.

Lean improvement for pantograph jack production process using Value Stream Mapping

The objectives of this research are to study the current process and improve the production process of pantograph jack by using Lean manufacturing techniques. The Lean tool used is Value stream mapping (VSM). The study starts with collecting data from the upstream to downstream to create a Current-state VSM to identify wastes and problems. The first problem was the low efficiency of the production process due to the high lead time of 7 days 8 hours. The ratio of value-added time to the lead time was only 0.026%. The next problem was overproduction because the cycle time is 69.54 seconds/piece while the takt time is 140.15 seconds/piece, which is 46.62% of the takt time, resulting in the early stoppage of the production line to prevent over inventory of finished products. After identifying the problems, the next step is to define production process improvement approaches by creating a Future-state VSM. The tools for the improvement included the Kanban system, Supermarket, Line balancing, and Cellular manufacturing then a simulation model of both current and future states was created to compare the results before and after the process improvement. The result from the simulation shows that the total lead time was reduced to 4 hours 39 minutes or a decrease of 97.54% from the current state. The ratio of value-added time to the lead time was increased to 1.304%, which is 49.39 times more than before the improvements, and the cycle time was increased to 133.02 seconds/piece, which is 94.91% of the takt time.

Assessing the transition from mass production to lean manufacturing using a hybrid simulation model of a LEGO® automotive assembly line

PurposeWith hybrid simulation techniques getting popular for systems improvement in multiple fields, this study aims to provide insight on the use of hybrid simulation to assess the effect of lean manufacturing (LM) techniques on manufacturing facilities and the transition of a mass production (MP) facility to incorporating LM techniques.Design/methodology/approachIn this paper, the authors apply a hybrid simulation approach to improve an educational automotive assembly line and provide guidelines for implementing different LM techniques. Specifically, the authors describe the design, development, verification and validation of a hybrid discrete-event and agent-based simulation model of a LEGO® car assembly line to analyze, improve and assess the system’s performance. The simulation approach examines the base model (MP) and an alternative scenario (just-in-time [JIT] with Heijunka).FindingsThe hybrid simulation approach effectively models the facility. The alternative simulation scenario (implementing JIT and Heijunka LM techniques) improved all examined performance metrics. In more detail, the system’s lead time was reduced by 47.37%, the throughput increased by 5.99% and the work-in-progress for workstations decreased by up to 56.73%.Originality/valueThis novel hybrid simulation approach provides insight and can be potentially extrapolated to model other manufacturing facilities and evaluate transition scenarios from MP to LM.

Barriers and strategies for sustainable manufacturing implementation in SMEs: A hybrid fuzzy AHP-TOPSIS framework

Due to growing sustainability challenges, small and medium-sized enterprises (SMEs) are under tremendous pressure to implement sustainable practices in their operations. Studies in this regard show that in almost all cases, transition from a traditional approach to sustainable manufacturing is not at all a smooth experience as it is fraught with pitfalls on several counts at the implementation stage. Therefore, analyzing probable barriers and implementing right set of strategies duly addressing them becomes utmost crucial to successfully implementing the sustainable manufacturing practices. The study particularly aims at identifying and prioritizing such strategies to overcome the very barriers in the implementation phase. The study identified some twenty one odd barriers through an extensive literature review and expert opinions and classified them into four categories. In the same way, nine specific strategies were identified to address the barriers through a comprehensive literature review. An Integrated Fuzzy Analytical Hierarchy Process-Fuzzy Technique for Order of Preference by Similarity to Ideal Solution (FAHP-FTOPSIS) approach has been used to further prioritize the barriers and strategies for sustainable manufacturing implementation in Indian manufacturing SMEs. The result depicts that, “Ineffective enforcement of the law (B22)”, “Complexity in implementing 6Rs (B17)”, “Ineffective controlling and monitoring system (B24)”, “Need for a standardized approach to carbon auditing (B15)” and “Heavy dependence on fossil fuels (B14)” are the top five barriers that hamper smooth implementation of sustainable manufacturing whereas, out of the nine proposed strategies “Implementation of lean and green manufacturing techniques (S2)” and “Establishment of benchmark and performance measuring systems (S6)” were found to be the two most important strategies that should be employed to eliminate the identified barriers. The findings provide strategic insights into guiding decision-makers and practitioners of Indian manufacturing SMEs in regards to sustainable manufacturing implementation. Besides, this study also assists managers by way of providing them with a hierarchical list of strategies ranked in order of their effectiveness to potentially eliminate the implementation barriers.

Performance optimization of pillow sheet set sewing assembly line by SAM analysis and lean manufacturing techniques of method study & work measurement

This research was conducted to enhance the productivity of the targeted sewing line at the ABC textile company. The existing SAMs, the capacity of the sewing line for various operations, and several required machines were collected. Moreover, the obtained figures were observed and analyzed by using time study and motion study, and certain improvements were made at the sewing line. Results indicated that SAMs for operations A and B were minimized by -13.64% and -14.54% respectively; whereas, SAM for operation C was increased by 16.67%. Machine requirement for operation C was increased by 100%; moreover, the capacity for operations A, B, and C was increased by 12%, 12.69%, and 40% respectively. When it is to production activities, the little improvements play a significant role in boosting the productivity of the production system. Optimal allocation of human resources, machines, and time are the benefits of line balancing. This can be made possible with the application of the line-balancing framework. With every passing day, the nature and type of article vary at the sewing line thus it is highly needed for the company to get the model developed for an automated line balancing application. Moreover, this work can be extended by the development of a line-balancing framework considering the nature of production.

Productivity improvement using different lean approaches in small and medium enterprises (SMEs)

Small and Medium Enterprises (SMEs) play a crucial role in the Indian economy. To remain competitive in the global market, application of Lean Manufacturing Techniques (LMT) helps SMEs to improve their processes in alignment with customer needs. The purpose of this study is to reduce overall lead time by identification and eliminating non-value added activities (NVA) from the manufacturing system. In this paper, the current manufacturing processes have been thoroughly studied using the principle of work study. Several lean approaches such as- TAKT time computation, Value stream Mapping (VSM), layout optimization, Kanban, Andon etc. have been used to make improvement in line efficiency and hence productivity. The study shows that use of line balancing technique, matches the cycle time with calculated TAKT time. And the efficiency of the line has increased approx 10% and hence balance delay got reduced. Again VSM helps to reduce the lead time of foundry shops by 51 minutes. It is one of the few studies that deal with productivity improvement in Indian SME.

Proposal for application of overall equipment effectiveness indicator in a hot sauce company

The use of indicators within companies is highly relevant to help manage their processes. Particularly for equipment and machinery, the indicator of overall equipment efficiency (OEE) is commonly used with the objective of measuring equipment inefficiency and identify losses. This helps to foster an environment of continuous improvement that leads to increased productivity. During this investigation, an adapted methodology is used, which highlights the use of lean manufacturing techniques, from which our OEE metric is derived. The purpose is to know the efficiency of the equipment in order to take actions that help reduce the waste presented in a production line of a hot sauce company. This article will contribute to the promotion of the use of new tools that lead to continuous improvement, since our intention is to simplify the way the company visualizes its problems, which will lead to finding solutions in a faster and more objective way.

Lean Manufacturing Structural Model for Improving Operational Performance of Diverse Industries

The benefits of employing Lean Manufacturing (LM) on industrial organizational performance is still an ongoing debate. This paper aims to explore the impact of implementing LM techniques on operational performance across different industries in Saudi Arabia. A structural LM model that is consistent with the Toyota Production System (TPS) was presented. For data collection in established companies a structured survey was used. Of the 120 companies contacted, 67 useful responses imply a response rate of 55.8 % were obtained. The structural and operational models have been evaluated using the Social Sciences Statistics Program (SPSS) and SmartPLS 3. The results showed that by implementing the specified LM tools, the operational performance can be enhanced.

Minimization of Non-Value-Added Activities in an Aerospace Industry

Abstract-- The industry was having lesser productivity than the required due to the presence of certain ‘non-value added’ activities. Hence, the requirement was to improve productivity by means of cost reduction and rationalisation of manpower. Since the main purpose was to eliminate any process that does not add value to the final output. To reduce the waste, the lean manufacturing is the best choice among the available techniques. The Value Stream Mapping (VSM) is one of the major components in lean manufacturing techniques. This helps in identifying the major opportunities for performance improvement in the assembly line of the aerospace industry. The Value Stream Mapping was developed in the required assembly lines of the aerospace industry. The Value Stream Mapping consists of Time-Study, 5s implementation and skill based line balancing at the required workstations. Time-Study was conducted at the bottleneck workstations. The results were analysed by categorising them as value added (VA) and non-value added (NVA) components. This has benefited in identifying waste in the assembly line. The activities which were not adding value to the final product were eliminated and compared with previous results. Based on the analysis, the required man-power was added to improve the productivity. Keywords— Value Stream Mapping, Lean manufacturing, Time-Study, 5s, Productivity

Prospects and Challenges of Lean Manufacturing Deployment within Manufacturing SMEs in Nigeria: A Literature Review

Small and medium enterprises (SMEs) played a vital role in manufacturing goods for consumer and industrial purposes, making them instrumental in business growth and economic development. However, issues of poor quality and substandard products prevail due to limited technical knowledge that hindered them from competing locally and globally in Nigeria—arising from the lack of lean manufacturing deployment and implementation. Therefore, the study aims to provide an insight into the prospect and challenges of manufacturing SMEs in Nigeria as it relates to the deployment of lean manufacturing tools and techniques. The study would aid manufacturing SMEs in better comprehending their potentials and problems, hence, deploying lean manufacturing initiatives successfully. The study applied a literature review approach through past empirical and conceptual studies from reputable journals and reports. Based on the available literature, the study finds that though manufacturing SMEs in Nigeria are faced with numerous issues, e.g., poor leadership, lack of qualified personnel, and inadequate funds , they have shown higher prospects of deploying lean manufacturing successfully. The study concludes that manufacturing SMEs should bank on potentials like flexible organizational culture and structure, easy access to customers and suppliers, and flexible manufacturing system to deploy lean manufacturing, which will further aid in waste elimination, value addition, customer satisfaction, and enhanced performance. The study serves as the foundation for further empirical research on issues related to lean manufacturing deployment within SMEs, thereby proffering solutions to the quality challenges they are facing.
  

Reduction of Non-Value-Added Activities in An Aerospace Industry Using Value Stream Mapping and Time Study

Abstract: The industry was having lesser productivity than the required due to the presence of certain ‘non-value added’ activities. Hence, the requirement was to improve productivity by means of cost reduction and rationalisation of manpower. Since the main purpose was to eliminate any process that does not add value to the final output. To reduce the waste, the lean manufacturing is the best choice among the available techniques. The Value Stream Mapping (VSM) is one of the major components in lean manufacturing techniques. This helps in identifying the major opportunities for performance improvement in the assembly line of the aerospace industry. The Value Stream Mapping was developed in the required assembly lines of the aerospace industry. The Value Stream Mapping was used for other techniques like Time-Study, 5s implementation and skill based line balancing at the required workstations. Time-Study was conducted at the bottleneck workstations. The results were analysed by categorising them as value added (VA) and non-value added (NVA) components. This has benefited in identifying waste in the assembly line. The activities which were not adding value to the final product were eliminated and compared with previous results. Keywords: Value Stream Mapping, Lean manufacturing, Time-Study, 5s, Productivity