Lean Manufacturing Research Articles

The Implementation of Lean Manufacturing on Zero Waste Technologies in the Food Processing Industry: Insights from Food Processing Companies in Kosovo and North Macedonia

This study aims to investigate the impact of lean manufacturing (LM) practices in the food processing (FP) industries of Kosovo and North Macedonia. It focuses on examining the effects of LM practices on operational performance metrics and evaluating the challenges and opportunities in integrating lean principles with zero waste (ZW) technologies and sustainability objectives. A qualitative multiple case study approach was used to examine nine case studies from companies in Kosovo and North Macedonia, with four companies from Kosovo and five from North Macedonia. Semi-structured interviews, guided by themes derived from a comprehensive literature review, facilitated in-depth discussions on lean practices and their influence on operational metrics and ZW technologies. For analyzing the qualitative data, a thematic analysis approach was employed, involving a multi-step coding process that ensured a comprehensive exploration and interpretation of the data. The thematic analysis uncovered that LM practices, such as Just-In-Time (JIT), Total Productive/Preventive Maintenance (TPM), Statistical Process Control (SPC), and employee involvement, considerably improve efficiency, quality, and responsiveness. The results demonstrate a close relationship between LM practices and sustainability goals, especially in waste reduction and resource optimization. Identified challenges include organizational resistance to change and resource constraints, while opportunities for improvement were noted in employee involvement, supplier engagement, and continuous improvement initiatives. This study underscores the potential of LM methodologies to boost operational performance, foster sustainability, and tackle specific challenges within the industry, offering key insights for enhancing sustainable food production in both Kosovo and North Macedonia.

Integrating Lean Manufacturing with Industry 4.0: The Impact on Indian MSMEs

This research delves into the integration of Lean Manufacturing principles with Industry 4.0 technologies, exploring the emergence of "Lean 4.0" within the distinct operational context of Indian Micro, Small & Medium Enterprises (MSMEs). Recognizing the unique challenges and opportunities faced by businesses, the study adopts a robust mixed-methods approach. We combine rich primary data collected from 150 Indian MSMEs through in-depth interviews, insightful site visits, and comprehensive questionnaires. These firsthand accounts are further contextualized within a broader framework of existing literature and relevant case studies on Lean 4.0, providing a multifaceted perspective. Through rigorous data analysis conducted using R, the study illuminates the current landscape of Lean 4.0 adoption within Indian MSMEs. We go beyond simply documenting adoption rates, aiming to uncover the specific barriers hindering wider implementation. Crucially, the research critically assesses the tangible impact of Lean 4.0 integration on organizational efficiency, providing valuable insights for both practitioners seeking to optimize their operations and policymakers aiming to foster a more competitive manufacturing sector within India's diverse economic landscape.

Diagnostics of production processes using selected Lean Manufacturing tools

Diagnostics of production processes using selected Lean Manufacturing tools

Lean manufacturing for reducing lead time in foundry processes: a design science approach

Purpose The lean manufacturing (LM) approach is a highly effective method that can be implemented in any industry to streamline production processes, meet customer demand and eliminate any unnecessary waste. This paper aims to propose and evaluate a generic project-based framework grounded on the LM approach for reducing lead time in foundry processes. Design/methodology/approach Using design science research (DSR), we developed a generic LM project-based framework for reducing lead time in foundry processes. Findings The developed framework provides an alternative method to implement LM projects to reduce lead time and nonvalue activities in foundry factories. Practical implications The findings of this research can guide better lean practitioners for lead time reduction in foundry processes. Originality/value This paper contributes to the operational excellence literature when discussing the impact of the LM approach on foundry processes. In addition, the paper provides a roadmap for reducing lead time in a foundry company.

Line Balancing Study Using Value Stream Mapping Tool on Lean Manufacturing: A Case Study in an Electronic Industry

XY Electronics, a leading international company in electronic components manufacturing, is confronting significant production constraints that adversely affect output, lead times, and operational expenses. This study examines the manufacturing line for product A using Value Stream Mapping to analyze process times and identify bottlenecks where takt times are exceeded. It focuses on areas surpassing production cycle times and aims to enhance line utilization through better line balancing and waste reduction. The results reveal that the header assembly, along with coplanarity and pre-testing 3, are major bottlenecks, which significantly impact productivity. By optimizing task allocation, refining workforce distribution, and employing cross-training, the production line efficiency improved significantly. In addition, strategic workforce reallocation and station optimization were crucial in addressing resource underutilization and enhancing overall operational efficiency

Improving operations through a lean AI paradigm: a view to an AI-aided lean manufacturing via versatile convolutional neural network

Improving operations through a lean AI paradigm: a view to an AI-aided lean manufacturing via versatile convolutional neural network

ОЩАДЛИВЕ ВИРОБНИЦТВО: ІННОВАЦІЇ УПРАВЛІННЯ ПРОМИСЛОВИМ ПІДПРИЄМСТВОМ

The main problem is that the implementation of lean production requires not only technical changes, but also significant transformations in the organizational culture of the enterprise. Many Kazakhstani industrial enterprises face difficulties in the integration of lean principles due to the low level of awareness of management and personnel, insufficient training of personnel, as well as resistance to change, which is characteristic of many organizations. The purpose of the article is to research innovative approaches to the management of industrial enterprises by implementing the principles of lean production, as well as to develop a methodology that would facilitate the effective application of these principles in practice. The object of the study is the management processes of industrial enterprises in the context of the implementation of the principles of lean production. The methodological basis of the research was the logical methods of information processing, statistical analysis, comparison. The main hypothesis of the study is that innovations in the management of industrial enterprises, based on the principles of lean production, ensure the effective functioning of the enterprise in the long term due to the integration of the latest management practices that take into account the specifics of the domestic market and available resources. Presenting main material. The study covers the study of existing management practices, personnel training methods, and organizational culture transformation necessary for the successful implementation of lean manufacturing. Lean manufacturing is a modern concept of production process management aimed at reducing costs, improving product quality, and satisfying consumer needs. This approach, which was developed in Japan, in particular at the enterprises of the Toyota company, is now widely used all over the world, including Ukrainian industrial enterprises. Implementation of the principles of lean production requires not only technical changes, but also significant transformations in the organizational culture of enterprises, which is a complex and multi-stage process. Originality and practical significance of the research. In practice, the successful implementation of lean manufacturing requires a comprehensive approach that includes both technical and organizational measures. One of the key aspects is the adaptation of the best global practices to the specifics of a particular enterprise. For example, heavy industry may require longer staff training and a more thorough approach to change planning. Conclusions. The implementation of lean production is a strategic step that allows to increase the competitiveness of the enterprise, to ensure its sustainable development and successful functioning in the conditions of the modern economy.

Strategies for economic sustainability: An empirical study on Muri, Mura, and Muda in the readymade garment sector

Achieving economic sustainability in the garment manufacturing industry necessitates the implementation of several strategic measures. Basic strategies like adoption of automation, utilization of sustainable energy sources, diversification of markets and products, enhancement of supply chain resilience, etc. lead to the attainment of economic sustainability in the garment manufacturing industry. Additionally, the underlying component of these strategies for ensuring economic sustainability is the minimization of process waste, which can be effectively achieved through the application of lean manufacturing principles, specifically targeting the elimination of Muri, Mura, and Muda. This strategic commitment ensures business longevity amid evolving industrial landscapes, fostering innovation and competitiveness. In emerging economies like Bangladesh, pinpointing precise approaches to reduce waste is vital. This study explores into Muri, Mura, and Muda in the RMG sector, utilizing Pareto analysis, Fuzzy theory, Total Interpretative Structural Modeling (TISM), and Matriced’ Impacts Cruoses Multiplication Applique an un Classement (MICMAC) analysis. After the initial identification of 21 (twenty) factors, Pareto analysis pinpointed the primary 16 (sixteen) factors. Subsequently, these factors underwent analysis through fuzzy TISM and fuzzy MICMAC. The results highlighted “Demand variation”, “Supplier variation”, “Workforce variation”, and “Energy supply variation” as the most crucial factors. The novelty of this study lies in exploring Muri and Mura factors in correlation with Muda employing the existing hybrid and effective methodology that combines Pareto analysis, Fuzzy MICMAC, and Fuzzy TISM methodologies. It offers fresh perspectives on their significance for economic sustainability in the garment sector. Prior research has not explored this integrated approach to reduce process waste by addressing Muri and Mura factors in emerging economies’ garment industries. This research is poised to significantly impact waste reduction in the RMG sector, enhancing competitiveness, appealing to environmentally conscious consumers, and ensuring industry standards adherence essential for sustained success. The contribution of this research is grounded in helping the practitioners and entrepreneurs in developing nations make strategic choices that will lead to the RMG sector’s resilience and, ultimately, economic sustainability.

Innovative paths to productivity: Advancing lean manufacturing in industrial engineering

Innovative paths to productivity: Advancing lean manufacturing in industrial engineering

Overviewing Challenges and Solutions in Lean Manufacturing Implementation for Domestic Enterprises

Companies keep focus on enhancing the quality, efficiency, and customer satisfaction of their products and services while at the same time increasing their profits. Lean Manufacturing emerges as a potent strategy to address these imperatives via identifying and eliminating losses. Hence, it leads to optimized production processes and enhances overall performance of enterprises. This study presents an overview and analysis of lean manufacturing principles, implementation strategies, challenges, and economic benefits for Ukrainian enterprises. The main hypostatize of the paper was to investigate whether the Lean manufacturing approach is associated with different scope of businesses and whether it brings efficient outcomes for all of them. Based on conducted structured literature review the study highlights the versatility of lean methodologies across various industries and administrative processes. Employing scientific methods like comparative analysis and theoretical generalization, the research offers insights into the outcomes of lean implementations, including cost savings, productivity enhancements, and improved product quality for business organizations. The main outcomes of study underscore the critical role of strong leadership commitment and organizational culture in driving successful lean transformations. Through overviewing case studies and practical insights, the article illustrates real-world applications of lean manufacturing principles from different industries, exemplified by organizations AeroStar, Nova Poshta and Boeing. The paper is theoretical. However, the study advocates the practical importance of adoption of lean principles to achieve operational excellence for companies regardless of their scope of operating activities. Also, it offers suggestions for future research to explore emerging technologies' impact and cross-cultural comparisons in lean manufacturing practices.

DEVELOPING SOFT SKILLS OF FUTURE PSYCHOLOGISTS IN THE EDUCATIONAL PROCESS

In the professional environment, it is common to divide skills into two types: soft and hard skills. The former help to solve life challenges and interact with other people, while the latter help to achieve the best results in a particular profession. It is emphasized that soft skills are skills that each of us has, but not everyone has reached a high professional level. Soft skills help to solve life problems and work with other people. Not everything always goes smoothly, and a future psychologist must be able to cope with difficulties, take responsibility, and look for solutions. To do this, they need to be able to communicate, defend their ideas, think critically, and work in a team. It has been proven that if students do not have the desire to develop, it will be difficult to improve soft skills and change themselves. Though everyone possesses soft skills, they do not all reach the high level. The main success lies in getting feedback and analyzing the stage they have passed - without all this, it will be extremely difficult to move on. It has been found that customer focus, project management, mentoring, non-violent communication, decision-making, problem solving, emotional intelligence, learning ability, working under uncertainty, lean manufacturing, ecological thinking, self-reflection are effective methods of developing soft skills. The article describes the specifics of developing students’ soft skills who are future psychologists.

Reduction of Setup Times in a Metal Fabrication Company Using a Lean-Sigma Approach

Manufacturing companies face demand fluctuations and must deliver the required quantity of parts to their customers within the required time; however, companies face different challenges in fulfilling them. One is technological advances, which make it impossible for them to compete with other countries, such as China, due to financial issues. Therefore, manufacturing companies use continuous improvement methodologies to achieve better performance in their processes. Six Sigma and Lean Manufacturing are some of the best-known approaches. This article briefly presents the application of a lean sigma approach oriented to solving problems. This research proposes a methodology based on Lean Sigma that contrasts what different authors currently do: continuous improvement projects that take up to 12 months to produce results and do not solve a problem. This implementation is conducted in a process that manufactures metal parts and fails to deliver them on time to its customers. Using tools such as the Single Minute Exchange of Die (SMED) in a production line, on-time deliveries were increased from 89 % to 96 %; at the same time, the model change times were reduced by approximately 60 %, which is required for the implementation of this methodology for only four weeks, unlike the traditional six-sigma approach that can take up to 12 months to improve the process.

A model to access the productivity of an agricultural implements consortium: a case study

Purpose This work presents the results of a case study aimed at revitalizing an agricultural equipment manufacturing consortium facing prolonged losses. The purpose of this paper is to enhance productivity and profitability by identifying and eliminating waste within the manufacturing processes. The study uses lean principles and tools to achieve this objective. Design/methodology/approach The study begins with the creation of a questionnaire, administered to the consortium to gather insights. The questionnaire responses serve as a foundation for pinpointing critical areas in need of immediate attention. To tackle the challenge of demand forecasting without customer data, a demand forecasting model is introduced. Value stream mapping (VSM) is used to identify and highlight process inefficiencies and waste. The findings are further analyzed using a Pareto chart to prioritize waste reduction efforts. Based on these insights, the study proposes alternative manufacturing methods and waste elimination strategies. A multiphase lean framework is developed as a step-by-step roadmap for implementing lean manufacturing. Findings The study identifies a broken process flow within the consortium’s manufacturing processes and highlights areas of waste through VSM. The Pareto chart analysis reveals the most significant waste areas requiring immediate intervention. Recommendations for process improvements and waste reduction strategies are provided to the consortium. Originality/value This study contributes to the field by applying lean principles and tools to address the unique challenges faced by an agricultural equipment manufacturing consortium. The integration of a demand forecasting model and the development of a multiphase lean framework offer innovative approaches to enhancing productivity and profitability in this context.

Амбулаторнодополняющие технологии в условиях формирования «Новой модели медицинской организации, оказывающей первичную медико-санитарную помощь».

Purpose: propose new terminology “outpatient complementary technologies” in the provision of primary health care and justify their use. Materials and methods. Guidance documents, reports, open literary sources, orders, directives of the Russian Ministry of Health were analyzed. Results. The primary link of domestic health care is currently becoming more and more actively developed. The reason for this is the implementation of the tasks of national projects in order to achieve their most important key indicators. The successful implementation of lean manufacturing technologies into the practice of medical organizations providing primary health care within the framework of the “New Model of a Medical Organization Providing Primary Health Care” has shown its effectiveness. Undoubtedly, all this is facilitated by the significant economic growth of our country, accompanied by an annual increase in healthcare funding. In primary care medical organizations, special attention is paid to the organization and quality of preventive measures, as well as the successful conduct of dispensary work. This direction contains such factors as the formation of a healthy lifestyle, assessment of the existing risks of diseases, the presence of which requires timely treatment and observation. The ongoing therapeutic and preventive measures are, of course, aimed at increasing the life expectancy of the population of our country. The modernization of primary healthcare, which began in 2020, is one of the priorities for healthcare development in the coming years. This allows us to improve the accessibility of medical care and smoothly move to a completely new level of quality of medical care, achieving the maximum level of patient satisfaction. Conclusion. The modern development of healthcare in the Russian Federation lies in the most intensive use of all modern, latest medical technologies, in particular, in the provision of primary health care. As part of its development, significant changes are taking place in professional terminology. A thorough study of the possibility of introducing and widespread use of modern, cutting-edge medical technologies in medical organizations providing primary health care allowed us to propose a new, not previously encountered, concept of “outpatient complementary technologies” and justify its existence. A definition of the new terminology with the prerequisites for its emergence is given and prospects for further development are proposed. As part of the project “New model of a medical organization providing primary health care,” the introduction of the use of the concept of “outpatient complementary technologies” is aimed at improving the efficiency of activities and improving the system for organizing the provision of primary health care.

Analisis Pengurangan Waste Proses Produksi Pada PT SP Manufacturing

PT SP Manufacturing is a manufacturing company that operates in the field of wire harness production. When making wire harnesses at PT SP Manufacturing, waste still occurs. Waste in the production process is one of the biggest problems this company wants to solve. A defective product is a product that does not meet wire harness production standards so it cannot meet customer demand, and requires more space before rework is carried out, which causes inventory waste (Unnecessary Inventory). Reduced productivity and higher production costs are the result of this waste. The aim of this research is to use value stream mapping to identify waste in the production process and apply lean manufacturing techniques to reduce it. The results obtained are based on identification and analysis of existing problems as well as alternatives and improvements based on the formulation and objectives in the research. The largest waste in the wire harness production process of PT.SP Manufacturing is waste with a weight score of 60.89%, unknown inventory waste with a weight score of 39, 12%. The causal factors are workers who lack concentration, apply excess solder paste to the wire terminals, workers who pursue targets without paying attention to quality, resulting in defective products that require rework. The recommendations given to the company according to the fishbone diagram are proposed improvements to the wire harness production process to reduce defects and unnecessary inventory which refers to people, machines, methods and materials.

Analysis of Value Stream Mapping (VSM) in the Application of Lean Manufacturing to Minimize Waste at PT. Karya Indah Medika

Achievements to minimize waste can be done by adopting a Lean manufacturing approach. Lean manufacturing is a concept that can design production processes to be better, faster, and cheaper with minimal space, small inventory, small labor hours, and avoid waste. This research takes the case study of PT Karya Indah Medika which is a company engaged in manufacturing to produce medical devices, medical device service services, and medical device installation. In the company there is still waste, especially in unnecessary movements and product defects. This study aims to identify waste that occurs in the company and provide recommendations for improvements in order to minimize waste and obtain optimal production time. Value stream mapping is used to describe all processes in the company. The results showed that the initial production time of 17 hours 18 minutes could be reduced to 1 hour 55 minutes. Based on the Failure Mode and Effect Analysis (FMEA) it is known that the root cause of the problem in the highest waste is workers in a hurry so they are not thorough in working with a Risk Priority Number (RPN) score of 294, lack of materials needed for production, placement of tools that are not in accordance with production needs and a warehouse area that is less extensive by 216.

Implementation of lean manufacturing in a pharmaceutical distribution center: a case study

The present work aims to provide a brief case study of a distribution center of a major Brazilian pharmaceutical retail company. Initially, a quick literature review is presented regarding the fundamental concepts of Logistics, as well as its primary activities according to the most traditional literature, the concept of a distribution center, and the important characteristics for its proper functioning, and finally, the delimitation of the lean philosophy, elucidating key points to be used in its implementation. The study showed that, within a context of continuous improvements, lean practices implemented in production, such as VSM, are a powerful tool for diagnosing and repairing deviations. Thus, it is understood that the lean logistics philosophy is indeed key to the proper functioning of companies in general, especially for large distribution centers, whose merchandise flow depends on robust logistics at the end of the production chain.

Industry 4.0 and sustainability: the case of the Italian textile district of Prato

PurposeThe purpose of this paper is to analyze the twin transition of textile firms operating in an industrial district. The twin transition comprises two interconnected but distinct processes: the sustainable transition and the digital transition. The study specifically considers sustainability goals in terms of the triple bottom line and digitalization as the adoption of Industry 4.0 (I4.0) technologies. The study aims to understand how the characteristics of Italian districts influence the choices related to the twin transition and how it affects textile industrial firms.Design/methodology/approachThe author conducts a multiple-case study involving five firms of industrial textile district of Prato.FindingsThe results show the relationship between the characteristics of the district, such as fragmentation of the supply chain, lean manufacturing, territorial proximity and attachment to origins and traditions and the sustainable goals and I4.0 technologies adoption. Moreover, the study proposes a framework for twin transition. Market and technology drive the process in which sustainability represents the aim, I4.0 serves as enablers and the relevant outcome is the implementation of the business model innovation.Practical implicationsThese findings offer valuable insights for textile firms, policymakers and stakeholders seeking to navigate the complexities of twin transition.Originality/valueThe study contributes to the broader topic of twin transition. In particular, it links the particular context represented by the industrial district in which the textile firms operate to their conduct, and the two interconnected and distinct processes, sustainable transition and digital transition, with the business model innovation topic.

Enfoque metodológico para el aprovechamiento de mermas de transformación agrícola basado en manufactura esbelta: Caso de estudio en una finca cafetera en Colombia

Improvements in production systems that use the lean manufacturing approach known as “Lean” have the objective of eliminating or reducing waste or process inefficiencies (muda). This approach is increasingly adopted by different industrial sectors, including agriculture. Although Lean improvements are traditionally applied to existing processes from cultivation to distribution, opportunities to intervene in processing wastes (losses) are left aside. This article presents a methodological approach framed in five Lean principles, made up of six activities aimed at the design of new processes that make use of the losses generated by harvesting and agricultural transformation. The methodological approach is applied in a Colombian coffee farm where parchment coffee transformation processes are developed. A parallel losses composting process is designed that transforms defective, green, overripe beans, coffee pulp, mucilage and husk. The results show that by applying the methodological approach on the coffee farm, a level of losses transformation of 86% is achieved. Molting is also reduced for both the current parchment coffee production line and the composting line to 35% and 50% respectively. The main reductions are reprocessing and waiting times. Finally, a 30.3% reduction is obtained in the time of activities that do not add value, making both the current and proposed processes more efficient and with better delivery times.

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

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