Lean Manufacturing Research Articles

A Review on the Implementation and Effectiveness of Lean Manufacturing Strategies for Industrial and Service Sectors

Ensuring a neat, clean, organized, safe, and productive workplace is essential for every organization. Waste and abnormalities may lead to a high loss of productivity and, consequently, capital, along with a significant compromise to the health and safety of the stakeholders. To overcome such challenges, Lean manufacturing is implemented worldwide. The main aim of this technique is to reduce or eliminate certain types of waste (such as those related to motion, transportation, overproduction, waiting time, etc.) that may contribute to financial loss for the companies. The Lean technique is hybridized with other industrial engineering methods such as DMAIC, Six Sigma, Kanban, etc., depending on the situation. This paper reviews some of the vital work in the last five years on implementing Lean manufacturing for various industrial, commercial, and service setups. It first introduces Lean manufacturing, discusses its implementation procedure and tools and techniques, and presents an analysis of previous attempts made by researchers and engineers using Lean to minimize waste, maximize productivity and efficiency, and enhance quality. The article ends with concluding remarks and highlighting the directions for future research. The novelty of this article lies in the fact that along with a basic introduction and review of the last five years’ literature, it also sheds light on current trends; recent developments; Lean integration with Six-Sigma, Kanban, Kaizen; automation and digital technology interventions to increase the effectiveness of Lean manufacturing; contribution of Lean in sustainable development.

The Effect of Lean Manufacturing on Production / Operation for the Small and Medium Enterprise in Malaysia

At the start of 2022, the government announced its focus on supporting the development of small and medium enterprises (SMEs) to improve living standards following the COVID-19 pandemic. SMEs contribute significantly to the national economy, with the clothing industry playing a major role. This research applies lean manufacturing techniques to enhance the performance of SMEs in the clothing sector, specifically in T-shirt printing. Therefore the first objective was to collect, analyze processing times and recording of all issues encountered during production. The second objective involved using value stream mapping (VSM) to analyze the T-shirt printing process from raw material supply to finished product packaging. We also employed a why-why analysis to pinpoint the underlying causes of inefficiencies and devise specific solutions. The last objective focused on process improvement using VSM, along with the Kanban system, 5S and Make to Stock (MTS) to optimize block preparation and T-shirt printing. We selected Flexsilk Printshop as the case study. The findings showed a 66.59 % reduction in waiting time, a 30.77 % improvement in lead time, an increase in overall equipment effectiveness (OEE) from 93.3 to 97.45 % and a 50.41 % increase in efficiency.

Environmental sustainability from a decoupling point perspective

Combatting climate change is of global importance. The fact that all UN member nations have agreed on the sustainable development goals (SDGs) is testament to this. The manufacturing industry plays a crucial part in meeting these goals. However, if manufacturing firms are to improve in terms of sustainability, such efforts must be reconcilable with their ability to make profit. Hence, sustainability efforts must be adapted to firms’ individual context and competitive priorities.Focusing on environmental sustainability, this paper is the first to empirically investigate and compare the commitment to environmental sustainability practices (ESPs), and the outcomes of such practices, across make-to-order (MTO) and make-to-stock (MTS) manufacturing plants. Furthermore, the paper investigates whether the customer order decoupling point moderates the relationship between characteristics of lean and agile manufacturing and ESPs. Hypotheses are developed based on extant literature and tested. The results indicate that MTO plants experience more benefits related to manufacturing and financial performance from their ESPs than MTS plants. The data also show that the association between ESPs and the outcomes of such practices are more robust for MTO plants than they are for MTS plants. Plausible explanations for these results are discussed and the findings of the paper are connected to the contemporary topic of smart manufacturing, as well as potential policy implications. Suggestions for future research are also provided.

Adaptation of the OEE Indicator in the Footwear Manufacturing Sector in Mexico

The Lean Manufacturing philosophy has been adopted in recent years by companies that have traditionally manufactured their products with artisanal processes and now seek to be competitive in today's market. The adaptation of the concepts established in this philosophy in the local industry has been one of the main limitations in the successful application of this philosophy. One of the most important measurements in the area of Lean Manufacturing is the OEE indicator, which indicates the real capacity to produce without defects. This article presents an adaptation of this indicator and its implementation in one of the industrial sectors with the greatest impact in the Mexican Bajío region, such as footwear manufacturing. This adaptation of the indicator can be applied to any company in this sector.

Integrating Lean Manufacturing and Six Sigma: A Synergistic Approach to Enhance Quality and Operational Efficiency

This paper presents an in-depth analysis of integrating Lean Manufacturing and Six Sigma to achieve operational excellence. Lean focuses on reducing waste and increasing process speed, while Six Sigma emphasizes quality improvement through defect reduction and variability control. Combining these methodologies, known as Lean Six Sigma (LSS), creates a powerful toolkit for industries seeking to improve both efficiency and quality. Real-world examples from companies such as General Electric, Toyota, and 3M demonstrate the practical applications of LSS, highlighting the benefits and challenges of its implementation. This paper also discusses critical success factors and proposes future research directions in Lean Six Sigma.

Integration of lean manufacturing system with novel intuitive fuzzy syncretic lean frame work to improve the overall equipment effectiveness

Lean manufacturing embraces the principle of doing more with less by removing non-value-added activities from manufacturing processes to preserve effectiveness, flexibility, and profitability. Predictive maintenance in production stages are more critical since it involves machines which are prone to failure and a post failure maintenance stagnates the production which creates bottlenecks due to machine failures. Hence in this work a novel intuitive fuzzy syncretic lean frame work has been implemented to incorporate the need of intelligent systems. The framework is divided into phases which employs Fuzzy logic with embedded smart sensors for effective utilization of man machine and materials in order to improve the effectiveness of a production floor. A novel time based forecasting is done in the design phase which implements the lean tool Takt time. The manufacturing phase uses the sensors to determine the predictive maintenance of the machines thereby implementing continuous flow as the lean tool and the inspection phase uses smart sensor system for real time continuous monitoring of the machining process thereby incorporating Poka-yoke as a lean tool. Thus by implementing the framework the overall equipment effectiveness is achieved which helps in achieving continuous flow of products and defect free products in any production firm.

Do green practices and technologies mediate lean manufacturing’s impact on industrial performance? Evidence from the European manufacturing survey

Purpose This study aims to analyze the mediating role that green practices (GPs) and green technologies (GTs) play in the relationship between lean manufacturing (LM) and industrial performance (IP). It is suggested that GPs and GTs are crucial for transforming lean routines into enhanced performance that simultaneously meet current environmental requirements. Design/methodology/approach The hypotheses are tested using a mixed methodology, which includes a partial least squares structural equation modeling approach and a fuzzy-set qualitative comparative analysis (fsQCA) applied to a multisectoral sample from three European countries (Spain, Sweden and Croatia). Findings The results confirm that GPs mediate the relationship between LM and IP; however, in the case of GTs, this mediation does not appear to occur, although GTs emerge as a peripheral condition in the subsequent fsQCA. These findings highlight the need to avoid an exclusively technocentric approach and underscore the importance of implementing green organizational practices alongside technology investments to achieve successful lean initiatives. Practical implications It seems clear that managers should apply GPs, combined with LM, to improve sustainability and efficiency and should apply GTs once a more mature lean-green culture has been established. Originality/value In recent years, the scientific community has increasingly focused on the impact of implementing GPs and GTs on IP within LM plants. However, to the authors’ knowledge, no study has yet analyzed the combined effect of both initiatives. This paper seeks to address this gap by examining, in aggregate, the moderating effect of GPs and GTs on IP in LM plants.

The role of process monitoring devices and digital line balancing in achieving operational excellence in garment manufacturing

This study investigates the transformative potential of integrating digital technologies with lean manufacturing principles to address the evolving challenges in the garment industry. The industry demands high-quality products, rapid delivery, cost efficiency, and production flexibility to maintain competitiveness and sustainability. While traditional lean methods have focused on waste reduction and process optimization, the advent of digitalization offers unprecedented opportunities for enhancing operational excellence. This research specifically examines the role of Internet of Things-based Process Monitoring Devices (PMDs) and digital line balancing in achieving these goals. PMDs, integrated within a digital lean framework, facilitate continuous monitoring of machine performance and operator efficiency, providing real-time insights into operational processes. This real-time visibility enables data-driven decision-making and centralized analysis, fostering agility and responsiveness. Furthermore, this study presents a dynamic digital line balancing algorithm that optimizes sewing line configurations and workload distribution. This dynamic approach allows for real-time adaptations in production flows to mitigate bottlenecks and boost productivity. By exploring the synergistic relationship between PMDs, digital line balancing, and lean principles, this paper contributes to a comprehensive understanding of how digital solutions can revolutionize operational efficiency in the garment manufacturing sector.

Lean Manufacturing en la producción de alimentos: Revisión sistemática, análisis bibliométrico y propuesta de aplicación

In a changing environment, efficiency and adaptability are essential to improve business competitiveness. The present study analyzed the application of Lean Manufacturing in food production through a review of the scientific literature based in Scopus, using the PRISMA methodology and the Vosviewer and Bibliometrix software. From the bibliometric analysis, there is evidence of an increase in research on Lean Manufacturing in food companies since 2019, with an annual growth rate of 5.96%. Brazil and Peru stand out for their high scientific production, while Brazil and Belgium stand out in terms of citations. In addition, outstanding scientific collaboration between authors from South America and Asia is observed. Three relevant clusters were identified: principles, implementation tools and practical applications of Lean Manufacturing. The thematic mapping highlighted the concepts Cost Reduction, Process Monitoring, Six Sigma and Value Stream Mapping as the most prominent topics underlining the interest and applications in the scientific literature. The implementation of Lean Manufacturing in seven steps is proposed, facilitating the use of agile tools for process optimization and waste reduction in food companies. Lean Manufacturing contributes to improve the flow of products in the supply chain and to the sustainability of small and medium enterprises. Future research should focus on adapting Lean Manufacturing to various contexts and business models in the agri-food sector.

Manajemen Kualitas dalam Meningkatkan Efisiensi Proses Bisnis Perusahaan

In an era of increasingly fierce business competition, companies are required to improve efficiency in every business process. One of the crucial aspects that can support efficiency is the implementation of proper quality management. Quality management is a systematic approach to managing and improving the quality of products, services, and processes in an organization, with the goal of meeting customer expectations and achieving optimal efficiency. This research explores various quality management approaches such as Total Quality Management (TQM), Six Sigma, Lean Manufacturing, and ISO 9001. This approach has a focus on continuous improvement, elimination of waste, and increased customer satisfaction. This study uses a qualitative descriptive method to analyze the implementation of these models in improving the efficiency of the company's business processes. The results of the assessment from the media expert, Mr. Muhammad Ikhwan, S.Pd., M.Pd showed the feasibility of the media with an average score of 92.17%, while the assessment of the material expert, Mrs. Nurul Isnaeni, S.Pd, obtained an average of 96.19%, with the category of "Very Feasible" for all aspects. This study proves that Powtoon-based learning media is effective and feasible to use in the context of education.

A framework to assess the effectiveness index (EI) of the Indian SMEs to integrate lean and sustainability through combined fuzzy logic and systems approach

PurposeTo become a sustainable lean manufacturing (LM) system, an organization must be first distinctly cognizant of the terms “lean” and “sustainability” as they relate to the state of affairs of their particular industry and business. Next, the organization must identify and acquire the necessary qualities it needs to become sustainable in lean philosophy and its practices in the organization. The LM paradigm has been a top priority for many businesses; thus, this article is based on actual research done in Indian small and medium scale organizations to see how widely it is understood and implemented.Design/methodology/approachA framework was developed based on literature review and academic research. A preliminary analysis of a small number of small and medium-sized enterprises (SMEs) that, conceptually, summarizes and demonstrates the concerted efforts that a company may undertake to increase its leanness. This conceptual model was employed to create a questionnaire that was administered to survey the SMEs of India. The information gathered through this questionnaire was analyzed using the model developed by the researchers. Then fuzzy logic and systems approach were used to find out the effectiveness index (EI) of the organization.FindingsThe EI for system leanness at different organizational levels within an organization is determined using fuzzy logic and systems approach for 48 SMEs in different clusters. The average EI of the system was found to be 0.336 on a scale of 0–1 which indicates that the current state of lean implementation and its sustainability is very low and poor in Indian SMEs. This article outlines the key model components and describes how they were applied to analyze the data gathered from an industry study.Research limitations/implicationsThe research aims to make lean continuously sustainable by surfacing and eliminating the wastes in the Indian SMEs whenever it appears rather than using it as a cleaning tool. The present study was focused on India’s southern industrial areas and it was difficult to gather the information around the country due to its diverse industrial culture and geography. Hence, more research and the comparative study of the same that takes into account the various regions of the nation’s industrial lean behavior can be conducted.Practical implicationsThe generalized sustainable lean framework analyzed using fuzzy logic and systems approach gives the current effectiveness of the leanness in SMEs of south India. This model can be effectively implemented in other areas of the nation to identify the scenario of lean and its sustainability and a final comprehensive model can be developed.Originality/valueThere is a dearth of comprehensive studies on the assessment of sustainability of the lean philosophy in Indian SMEs. With the help of combined fuzzy logic and systems approach, the model developed in this study evaluates the sustainability of the lean methodology using the EI used in SMEs by taking into account both the lean and sustainability factors as well as enablers like customer satisfaction, ethics, innovation and technology.

Lean process mining: adopting process mining in lean manufacturing for dynamic process mapping and avoiding waste occurrence in real time

Purpose This paper aims to recommend a method entitled “lean process mining (LPM)” for mapping, analyzing and improving the material/information flows in the value stream of manufacturing processes. Design/methodology/approach The method is developed based on literature review and in-depth explorative research in value stream mapping and process mining approaches. The proposed LPM framework consists of three phases including as-realized process state, improvement strategies and reengineered process state. Hence, firstly, extracts the as-realized model, measures the identified wastes and identifies the sources of wastes. Secondly, implements prediction-recommendation-prevention strategies. Thirdly, reengineers the process model and measures the improved wastes. Findings It presents the applicability of the proposed approach in (1) online observation of manufacturing process behavior and tracing the process deviations dynamically in real time to identify the sources of waste; (2) avoiding defective products occurring during the production and eliminating the relevant derived wastes including wasted material, wasted energy, waste of labor, excess inventory, increased production lead time and wasted operational costs. Originality/value The practical application of LPM is illustrated through implementing it in a real-life manufacturing case. The outcomes prove the remarkable applicability of this method in lean manufacturing to avoid waste occurrence in the value stream.

Формирование корпоративной культуры бережливого производства в современных условиях

The current stage of development of the national economy is associated with the formation of technological sovereignty of the country. Harsh sanctions, existing restrictions on access to certain market segments, digitalization and other challenges form an explicit request to Russian business to transform approaches to the organization of production, aimed primarily at increasing labor productivity, which is possible due to several main factors: the development of the production and technical base, maximizing the use of people-human capital and optimization of organizational factors. The first factor is quite costly and time-consuming in terms of implementation. The development of human and organizational factors can be carried out through lean production tools, the main problem of which is the significant resistance of personnel to new introductions. The work of foreign and domestic scientists and practitioners in the field of lean manufacturing and corporate culture has been studied, which allowed to formulate the author's definition of “corporate culture of lean production”, which allowed to develop a model of corporate culture of lean production at three levels of management (TOP, Middle, Down Management). The proposed model of transformation of the existing corporate culture into a corporate culture of lean production is considered in three planes with the designation of the stages of formation of a new corporate culture. It is noted that only voluntary adherence to a new ideology can maximize the effectiveness of innovations.

Improvement of Productivity by Using Means of Lean Manufacturing, Just in Time, and Production Technology in Thai SMEs Manufacturing Industry

This study investigated the current situations, opportunities, and obstacles in manufacturing industry, and to create a model for improving the efficiency while reducing the levels of inventory. This study gathered information from in-depth interview using snowball sampling from 20 manufacturing companies in Thailand. The results revealed that the organization has implemented lean production principles as a strategic initiative to mitigate losses. The implementation of comprehensive work manuals, offered in diverse languages such as Thai, Burmese, Japanese, and English, serves as an additional mechanism to mitigate losses by ensuring clarity and understanding among the workforce. Furthermore, the integration of modern technologies, encompassing machine technology, robotics and artificial intelligence, is actively pursued to streamline production processes and consequently reduce losses. The results presented that companies refrain from adopting Just-In-Time production systems due to operational challenges associated with fulfilling customer orders. Specifically, frequent machine shutdowns for adjustments are necessitated, leading to elevated unit costs. Manufacturing companies in Thailand continue to harbor potential for growth, despite the inevitable rise in employee wages leading to increased operational costs. To navigate this challenging landscape, companies must remain adaptive, responding not only to shifts in customer preferences but also to advancements in technology, proactive examination of customer needs prior to initiating the production process, a paradigm shift from low-cost production to the premium-grade products addresses the demands of customers seeking superior product quality, and the process of broadening customer bases both overseas and globally, and the analysis of distinct customer groups in identifying new target demographics.

A Decision Support Model for Lean Supply Chain Management in City Multifloor Manufacturing Clusters

City manufacturing has once again become one of the priority areas for the sustainable development of smart cities thanks to the use of a wide range of green technologies and, first of all, additive technologies. Shortening the supply chain between producers and consumers has significant effects on economic, social, and environmental dimensions. Zoning of city multifloor manufacturing (CMFM) in areas with a compact population in large cities in the form of clusters with their own city logistics nodes (CLNs) creates favorable conditions for promptly meeting the needs of citizens for goods of everyday demand and for passenger and freight transportation. City multifloor manufacturing clusters (CMFMCs) have been already studied quite a lot for their possible uses; nevertheless, an identified research gap is related to supply chain design efficiency concerning urban CMFMCs. Thus, the main objective of this study was to explore the possibilities of lean supply chain management (LSCM) as the integrated application of lean manufacturing (LM) approaches and I4.0 technologies for customer-centric value stream management based on eliminating all types of waste, reducing the use of natural and energy resources, and continuous improvement of processes related to logistics activities. This paper presents a decision support model for LSCM in CMFMCs, which is a mathematical deterministic model. This model justifies the minimization of the number of road transport transfers within the urban area and the amount of stock that is stored in CMFMC buildings and in CLNs, and also regulating supplier lead time. The model was verified and validated using appropriately selected test data based on the case study, which was designed as a typical CMFM manufacturing system with various parameters of CMFMCs and urban freight transport frameworks. The feasibility of using the proposed model for value stream mapping (VSM) and managing logistics processes and inventories in clusters is discussed. The findings can help decisionmakers and researchers improve the planning and management of logistics processes and inventory in clusters, even in the face of unexpected disruptions.

Evaluation of OEE at Lifelong India Using Lean Practices: A Case Study

Today, the industry is facing issues related to nonvalue-added activities (NVA). By integrating lean practices, industries can systematically evaluate and enhance their overall equipment effectiveness (OEE), leading to more efficient and effective production processes. This alignment not only boosts productivity by eliminating nonvalue activities but also contributes to higher quality outputs and reduced operational costs as well. Manufacturers are required to use value-added approaches in their manufacturing management due to the intense rivalry in real-world markets and growing client needs. Through continuous improvement, lean manufacturing (LM) has been demonstrated to be a significant technique for getting rid of nonvalue-added operations in manufacturing organizations. OEE at Lifelong India is assessed using lean tools and techniques, including Pareto analysis, Why–Why analysis, Kaizen concept and evaluation of Kaizen ideas, as well as before-and-after comparison, in order to assess the operational performance of the organization. A questionnaire was designed with data collection in mind, and business professionals in the field were surveyed and contacted personally. This study indicates that widespread implementation of lean principles leads to an increase in OEE of 95.89%, a level of OEE that is unmatched in the industry and ensures flawless output.

Lean Manufacturing and Process Optimization : Enhancing Efficiency in Modern Production

This comprehensive article explores the transformative impact of lean manufacturing and process optimization in modern industrial settings. It delves into these methodologies' principles, tools, and benefits, highlighting their crucial role in enhancing operational efficiency, reducing costs, and improving product quality. The article presents key statistics and case studies, including Japanese automotive manufacturer's benchmark lean manufacturing model, to demonstrate the significant improvements in productivity, quality, and cost-effectiveness achieved through these approaches. It also discusses the implementation strategies for lean and process optimization, emphasizing the importance of leadership commitment, employee training, and technology integration. Integrating Industry 4.0 technologies with lean principles, termed Lean 4.0, is introduced as the next frontier in operational excellence.

Lean Manufacturing Implementation in Developing Countries:Evidence from Jordanian Industrial Companies

In today's fiercely competitive landscape, industries are increasingly embracing lean manufacturing strategies for survival. However, the adoption of lean principles in Jordanian manufacturing sectors remains relatively new. This study aims to evaluate the current state of lean adoption in Jordanian industries, focusing on its techniques, motivations, and challenges. Employing a quantitative methodology, surveys targeted Production, Operation, and Quality Managers in Jordanian organizations. Out of 300 distributed questionnaires, 176 valid responses were received, representing a response rate of 58.7%. The findings indicate a relatively low adoption of lean practices in Jordanian industries, though firms that have implemented lean report significant benefits, particularly in quality enhancement and cost reduction. Key challenges include inadequate training, a scarcity of experts, and complexities in small batch production. While the study's sample size is limited, caution is warranted in interpreting the results. Further empirical research is needed to quantify the performance benefits of lean adoption. This study sheds light on lean adoption in Jordanian manufacturing, informing knowledge development and guiding future efforts to promote lean practices in the industrial landscape.

EXAMINING THE INTEGRATION OF INDUSTRY 4.0 TECHNOLOGIES IN MANUFACTURING

The integration of Industry 4.0 technologies is transforming manufacturing, enhancing efficiency, flexibility, and sustainability. This research paper explores the application of key technologies such as artificial intelligence (AI), the Internet of Things (IoT), and big data analytics in the sector. By analyzing a comprehensive dataset that includes supply chain metrics from major corporations like Apple, Amazon, and Google, the study examines the impact of Industry 4.0 practices on critical supply chain performance indicators, including inventory turnover ratio, lead time, and customer satisfaction. Industry 4.0 technologies are reshaping supply chain management (SCM) strategies such as lean manufacturing, agile SCM, and cross-docking. AI and block chain are shown to significantly enhance supply chain agility and resilience. Companies that integrate these technologies tend to have more streamlined operations, shorter lead times, and higher customer satisfaction rates. Environmental sustainability practices are becoming increasingly important as businesses strive for more eco-friendly manufacturing processes. The study finds that organizations employing agile supply chain practices and leveraging advanced technologies often demonstrate superior operational efficiency and financial performance. The integration of these technologies also introduces challenges, such as increased supply chain complexity and risk management concerns. This paper provides a comprehensive overview of how Industry 4.0 technologies are revolutionizing manufacturing and supply chain dynamics. It highlights the future trajectory of smart manufacturing and emphasizes the need for continued innovation to address emerging challenges. The research offers insights into how companies can adapt their supply chain strategies to thrive in the evolving landscape of digital transformation and automation.

A holistic approach to kitting cart optimization and steel receiving analysis for process improvement

This paper investigates the optimization potential within the steel-receiving process and kitting cart management in modern manufacturing facilities. As evidenced by a 20% improvement at Asuruf Industrial, the study indicates how the increasing popularity of kitting, with its capacity to reduce assembly time and space through pre-sorted kits, synergizes with vital efficiency gains in steel receiving. The implementation of Lean manufacturing tools, coupled with strategic interventions, yielded significant operational enhancements, resulting in an annual savings of $121,143. This success reinforces that structured operational strategies and Lean tools are indispensable for elevating manufacturing productivity and profitability. Anticipating a 45 to 50% increase through automation and preventative maintenance, the study underscores ongoing improvements in the steel-receiving process, emphasizing the crucial role of teamwork and Lean principles in addressing industry challenges. This approach not only ensures heightened productivity and competitiveness in the manufacturing sector.