Lean Method Research Articles

Lean Manufacturing: Literature review and implementation analysis

This research article covers the implementation of lean manufacturing in the metalworking sector, this tool is of the utmost importance due to its objective, which is to minimize the losses produced in any type of manufacturing process, in a magnificent way of using the resources that They are essential. His focus is on customer satisfaction. Looking for the product to be delivered correctly at the right time and in the planned place, the objective of the article is to make known more about the influence of the lean manufacturing method in the metal mechanics sector. This research was developed by collecting research from indexed databases such as Scielo, science direct, repositories and Scopus. Of which 50 investigations were selected, taking into account criteria such as the year of publication and the title of the investigation. That is why within the 50 investigations 46 articles and 4 magazines, which were selected through a systematic process. It was chosen because of the similarity it had with our research, that is, 50% spoke of the influence of lean manufacturing and how it improved the manufacturing sector and what methods were used. 30% lean manufacturing that also spoke of improvement methods in manufacturing and 20% the implementation of lean manufacturing at a general level throughout the sector. Concluding, the implementation of lean manufacturing is a method that brings many benefits regardless of the size of the company. This is thanks to minimizing the losses produced in any type of process, it adapts and regardless of the magnitude of the process and goes hand in hand with continuous improvement.

Incremental Deep Neural Network Learning Using Classification Confidence Thresholding.

Most modern neural networks for classification fail to take into account the concept of the unknown. Trained neural networks are usually tested in an unrealistic scenario with only examples from a closed set of known classes. In an attempt to develop a more realistic model, the concept of working in an open set environment has been introduced. This in turn leads to the concept of incremental learning where a model with its own architecture and initial trained set of data can identify unknown classes during the testing phase and autonomously update itself if evidence of a new class is detected. Some problems that arise in incremental learning are inefficient use of resources to retrain the classifier repeatedly and the decrease of classification accuracy as multiple classes are added over time. This process of instantiating new classes is repeated as many times as necessary, accruing errors. To address these problems, this article proposes the classification confidence threshold (CT) approach to prime neural networks for incremental learning to keep accuracies high by limiting forgetting. A lean method is also used to reduce resources used in the retraining of the neural network. The proposed method is based on the idea that a network is able to incrementally learn a new class even when exposed to a limited number samples associated with the new class. This method can be applied to most existing neural networks with minimal changes to network architecture.

Augmented Reality to overcome Visual Management implementation barriers in construction: a MEP case study

Visual Management (VM) is an important Lean method to enhance information flow and reduce waste in construction. However, its adoption is hindered by several barriers. Scientific works mention that emerging technologies can support or replace conventional VM practices, but empirical evidence is missing. Based on an in-depth literature review, we derived the research questions (RQs), arguing if Augmented Reality (AR) could mitigate VM implementation barriers. Thus, a corresponding AR measurement model was developed. Through a case study of mechanical, electrical, and plumbing (MEP) installations in a multi-story apartment building, the RQs were answered using an AR head-mounted display (HMD). To gather the necessary empirical evidence, the data was collected through direct observations on-site and through semi-structured interviews. The study findings show that (1) AR provided time savings and generally satisfactory accuracy levels. (2) AR demonstrably reduced the training effort to better support MEP marking work. (3) The use of AR reduced the resistance to change to adopt VM practices, although concerns were raised about poor ergonomics and work safety risks. Future research activities should consist of investigating the potential of other emerging technologies to overcome the common Lean implementation barriers in construction.

Integrated system for the proactive analisys of risk infection in patient’s surgical route

Abstract Background The most common hospital safety incidents are Hospital-Acquired-Infections (HAI) and among these Surgical Site Infections (SSIs). Our study proposes the use of a proactive system to manage risk combining the new Risk Identification Framework by WHO (IPCAF), the Lean method and the hospital’s Procedure Analysis. Each of the methods has pros and cons, and there is no existing literature that researches the concurrent use of all three methods. We focused on analysing patients’ surgical route to demonstrate that using an integrated system for preventing SSIs delivers enhanced results and significantly contibutes to a reduction in occurence of SSIs. Methods We conducted a retrospective observational study from 18 March 2019 to 20 April 2019 at Azienda Ospedaliera Universitaria Federico II di Napoli, Italia (Europa). The study is structured in 3 phases: Phase 1- application of proactive risk management tools (18 March- 15 April 2019); Phase 2-integration of results with the elaboration of a single system for proactive risk management (15-20 April 2019); Phase 3- collection of epidemiologic data concerning SSI. We used the incidence of surgical site as efficiency indicator (1-10 March 2022). The endpoints identified were: Primary Endpoint: a reduction of infection occurrence in surgical sites Secondary Endpoint: identification of critical points and control points within the surgical process with relevant corrective measures Results The rate of incidence of SSIs was selected as the efficacy indicator for the system. Our study recorded a 2.40% incidence rate for SSIs in 2020, compared to an incidence rate of 3.80% in 2018 and of 3.5% in 2017. Conclusions Considering the economic impact of the infections, along with the increased incidence of mortality and morbidity, employing all available tools to try and reduce SSIs incidence becomes paramount. A small reduction can produce significant cost savings that can be invested in other prevention programs. Key messages • Integrated system in proactively and promptly identifying risks related to patients’ surgical routes is effectiveness. • The system can be adapted to different healthcare settings, to prevent adverse incidents by employing a risk management strategy, and to further enhance existing strategies.

Integrated artificial intelligence effect on crisis management and lean production: structural equation modelling frame work

It is a goal that manufacturing companies strive towards on a regular basis, and it involves enhancing the efficiency and productivity of maintenance operations. It is especially vital to avoid unforeseen breakdowns, which may result in costly charges and production losses if they do not occur in advance. While the execution of an acceptable management plan affects maintenance productivity, it also affects the adoption of proper procedures and tools to help in the assessment processes in this field. This difficulty, among other things, affects a company's capacity to achieve high performance with the equipment it employs, as well as the judgement process and the design of the firm's maintenance plan. In order to achieve this goal, the aim of this paper is to exemplify how intelligent systems can be used to enhance judgement techniques in the implementation of the lean maintenance perspective, allowing for an advancement in the functional capabilities of the industry's technological infrastructure. The reseachers employed artificial intelligence technologies to look for connections between specific operations carried out as part of the deployment of lean maintenance and the findings achieved. The raw set notion, which was used in this situation, was used to determine whether or not the lean maintenance method was being used in this study. The crisis management process carries with it some of the most complex data technology concerns ever encountered. It necessitates, among other items, active information gathering and information transfer efforts, that are used for a range of functions, such as decreasing uncertainty, attempting to measure and manage consequences, and attempting to manage resources in a way that goes beyond what is generally possible to deal with daily problems. It also needs the employment of artificial intelligence technology, among other things, to increase crisis awareness.

Aligning key performance indicators with lean management in the service sector: A case study for a Jordanian telecommunication company

Lean implementation in the service sector has a dilemma related to defining the gap of the lean system and identifying the flaws in the processes which affect the overall performance and efficiency. This paper presents an innovative model that can help service companies to improve lean implementation and integrate appropriate Key Performance Indicators (KPIs) with the strategic goals. The aim of this paper is to also investigate different forms of waste that affect services performance by using the data of a global best practice. It also aims to apply and integrate the KPIs with Lean Management Tools to overcome the potential limitations of the traditional ones. As a first step of improvement, designing a new KPI lean method can lead to determining and reducing all different forms of existing wastes. Furthermore, such a method is expected to (i) improve the existing processes; (ii) enhance performance, (iii) increase time efficiency; and (iv) improve work accuracy. A new model that focuses on low-performance processes has been designed. The proposed model is also used to develop KPIs that are measurable and capable of detecting flaws and identify the possible improvements. When the model is continuously applied by service providers, the waiting time and non-adding value activities are expected to be significantly minimized. Likewise, monitoring and control of internal processes and activities can be improved. Furthermore, lean management is advantageous for the telecommunication sector as it allows a quick response to rapid changes in the telecom technology and, thus, improves the customer satisfaction.

Improving Creative Industry Production Performance during the Covid-19 Pandemic using Cost-Based Value Stream Mapping

Improvements in creative industry production performance during the COVID-19 pandemic is urgently needed to reduce production costs. Previous research has shown that improving industrial performance during the pandemic is still minimal. Implementing the lean manufacturing method using cost-based VSM is relevant to find out the industry's current value stream performance conditions and the potential savings in production costs. This research uses cost-based VSM to improve creative industry production during the COVID-19 pandemic. Based on the research results, three types of production waste are identified, i.e., motion, transportation, and inspection. Workstations have the most significant cost, i.e., tube making, making rings, and assembling. The lean action plan is then selected using several criteria: reducing lead time, increasing productivity, improving the quality of human resources, and increasing efficiency. With Implementing the lean action plan, process cycle efficiency is expected to increase by 5%, and production costs could be reduced by 0.45%.

Implementation of Lean Manufacturing With A Value Stream Mapping Approach to Improve The Efficiency of The Production Process

<p><strong>This research is based on the fact that many domestic sugar industries operate inefficiently and have low productivity, which is seen when compared to other countries such as Thailand, India and Australia. This study aims to identify and analyze problems along the flow of the white crystal sugar production process that cause waste and then make suggestions for improvements to reduce existing waste to increase cost efficiency in the production process. The national sugar factories generally have a basic problem, namely the low level of factory efficiency, which causes a lot of waste along the flow of the production process. The right concept for solving this problem is the implementation of the Lean manufacturing method, where this method focuses on efforts to reduce waste along the flow of the production process by making continuous improvements. The research begins with a literature study and field study and then conducts observations, analyzes, brainstorms, extracts and collects data from each work unit. The first stage begins with the define which will identify all forms of waste along the production process flow, measure to determine the most critical waste, analyze to identify the factors that cause waste in the production process, improve to carry out improvement plans, and reduce waste that occurs in the production process, and control as an evaluation of improvement results. The efficiency of the production process before the improvement is 78.7%, with improvements expected to increase production efficiency by 87.0% or an increase of 8.3 points.</strong></p><p><strong>Keywords</strong> - <em>Lean Manufacturing, DMAIC, Value Stream Mapping, Waste, Production Efficiency</em></p><p><strong><br /></strong></p>

Ideas and methods of lean and agile startup in the VUCA Era

In today’s volatile, uncertain, complex and ambiguous (VUCA) era, entrepreneurs face highly uncertain startup environments. Thus, traditional methods for launching startup businesses must address the challenges associated with uncertain environments. Based on the definition of startup as “the practical activity of starting a business in an uncertain environment”, the greatest challenge in startup is reducing uncertainty. Thus, this paper defines the lean and agile startup (LAS) method by using the business model canvas (BMC) as an iterative tool and combining the customer development (CD) method and agile method (AM). LAS is an upgraded version of lean startup (LS) that provides entrepreneurs with a “0-to-1” startup exploration method. It allows entrepreneurs to promote startup exploration activities through the “hypothesis-exploration-test-cognition” iterative model, thereby evolving their ideas into sustainable business models. Moreover, this paper articulates a developmental approach for building iterative startup software based on LAS. It therefore offers entrepreneurs a convenient and visual iterative tool for startup to improve the effectiveness of startup exploration.Supplementary InformationThe online version contains supplementary material available at 10.1007/s11365-022-00797-3.

Prototype Desain User Interface Aplikasi My School Menggunakan Metode Lean UX

Currently, Madrasah Aliyah Negeri 2, Tangerang Regency, has problems memorizing chapter 30 as a mandatory requirement for school graduation. The system used today uses a manual and simple method by using a memorization card provided by the school. This makes students find it difficult in terms of managing the memorization track record that students take. Not only students, but teachers find it difficult because they do not have a clear track record related to memorizing juz al-Quran where the memorization card can be torn, wet and even lost. Based on these problems, technology is needed that can assist students and teachers in managing the track record of memorizing al-quran juz 30. The technology uses the Lean UX to solve problems in the User Interface My School Application Lean UX. Using the Lean UX will make it easier for the school to get faster feedback from students and develop systems that do not yet exist in the school. From the evaluation obtained, that the prototype of my school application using the lean ux method can be accepted by users because it produces a percentage of the average value of usability testing of 81% to 100%, it can be said that the category is very feasible , which is worth 82%. Then in the validity test average value is above 0.220, which means that the data is valid. Furthermore, the reliability test produces a Cronbach Alpha of 0.928, where the magnitude of the reliability factor ranges from 0 to 1, and the higher the reliability factor, the more consistent the measurement results.

A Systematic Literature Review Examining the Lean Startup and Organizational Learning

The lean startup refers to a decade-old, practitioner-developed, hypothesis-driven entrepreneurship method that entrepreneurs use to develop scalable new products, business models, and enterprises by learning through experimentation. Since its introduction, the lean startup empiric literature has evolved, and opportunities exist to extend these works. This review engages the research question- What relationship does the lean startup have with organizational learning? Utilizing systematic and snowball techniques, this review engages 132 citations- 38 lean startup, 21 lean startup-related, 72 organizational learning, and 1 systematic literature review method. This paper offers multiple contributions to the literature. It identifies multiple characterizations of the lean startup. This analysis highlights that the lean startup situates well with multiple aspects of organizational learning- including process, behavioral, and cognitive. However, it finds limited evidence reflecting a direct effect of the lean startup on organizational learning. Accordingly, while this work does extend current publications, it sees the need to build on the extant literature, emphasizing lean startup’s direct influence on organizational learning. Emerging from this observation is a research question that captures this opportunity- How does the lean startup method’s use directly impact organizational learning in nascent ventures? Finally, from this question and considerations around the study’s findings and limitations, this review proffers multiple questions that define an agenda for future empiric research around these two phenomena.

Lean method for development of thermal treatment regimes for canned food from aquatic organisms for industry autoclaves

The article describes the lean method developed by the authors, which can be used in the development and scientific substantiation of experimental canned food heat treatment regimes for an industrial autoclave at the preliminary selection stage. The ways for improving the lean method to modernized using methods and means of automation are considered. The modernized method application will allow the fishing enterprises to increase efficiency within the lean production concept. The laboratory autoclave AVK-30M, the industrial autoclave ASCAMAT-230 and their automatic control systems are described. The description of experimental study for the development canned food heat treatment regimes is considered.

Implementasi Metode Lean Startup dalam Pengembangan Ide Bisnis Aplikasi Golek Kost Berbasis Mobile

The need for housing (boarding houses) for students is a basic need and becomes a significant consideration when deciding to study in a particular city. So far, students have obtained information related to boarding houses manually to meet the needs associated with the necessary furniture and in carrying out the moving process. With everything still manual, it takes longer and is more difficult to find a boarding house that fits the student’s needs. To help solve existing problems, a mobile-based application called GOLEK KOST was made. The application is a form of digital innovation to make it easier for students to obtain information related to boarding houses, including prices, locations and boarding facilities, buying, and selling furniture, transportation services, or moving services in the Yogyakarta area. Developing this application business idea applies the Lean Startup method, which consists of three stages: Market Validation, Product Validation, and Business Validation. This method focuses on developing applications based on feedback obtained from potential users so that later the resulting application will meet the needs of potential users. In the product validation, the results obtained are 37% for the boarding information feature, 33.3% for the transportation service feature, and 29.6% for the furniture sale and purchase quality.

Research on Lean Shipbuilding and Its Manufacturing Execution System

Abstract Based on the work breakdown structure theory, the lean shipbuilding method guided by intermediate products is proposed in this article. The hull segment task package is divided according to the content of the shipbuilding operation. Considering the constraints of resources and personnel at the production site, the scheduling strategy of the task package is formulated. Moreover, a virtual flow production system of the shipbuilding workshop is established. On this basis, a lean shipbuilding manufacturing execution system for small and medium-sized shipbuilding enterprises is developed to achieve lean production in a shipbuilding workshop. The application results indicate that implementation of the lean shipbuilding method and manufacturing execution system can significantly reduce the ship production cycle and the number of operators, as well as improve the production efficiency. Introduction In recent years, to resist strong international competition, manufacturers are under great pressure to develop products more efficiently and economically (Nam et al. 2016). The ship manufacturing industry, which faces fierce market competition, helps many nations’ economic systems (Rahman & Karim 2015). For example, the shipbuilding industry contributed over $37 billion of the Gross Domestic Product (GDP) to the U.S. economy in 2013 (MARAD 2015). Currently, China’s shipbuilding industry is in a downturn. If the shipbuilding enterprises want to survive and improve their competitiveness, they must reduce labor costs and shorten the production cycle. Lean production is a type of management philosophy born in Toyota Motors. One of the lean thinking goals is to eliminate waste, which can increase work satisfaction and turn waste into value. It should be emphasized that lean thinking must go beyond the company. In other words, lean thinking has to be employed from the product design to the set of activities delivered to the end customer (Barbosa 2014). Lean manufacturing technology focuses on eliminating all types of waste in the manufacturing process and reducing the lead time (Zhu et al. 2019).

New Product Development Using Lean Startup Methodology (Case Study : The Atsomee)

Fashion itself is one of the dominant sub-sectors in contributing to the economy in Indonesia. The Atsomee is a new player in the sustainable fashion industry selling clothing for women. With so many competitors in the same field, The Atsomee must continue to pursue and innovate. The need for new products is one of the crucial things in running a business in the fashion sector. In addition, the existence of product variants is very much needed for The Atsomee because it has spent several months without launching a new product. This study uses the Lean Startup method in developing its new product. The use of this method involves the customer/prospective customer in determining product development with the hope that the resulting product is in accordance with the needs and desires of the customer itself. This study uses interviews and questionnaires to determine product validation, market validation, and also business validation. The results obtained will then be used as the main data for the manufacture of new products for The Atsomee.

Identifikasi Faktor Kritikal Pendukung dan Penghambat Implementasi Lean Construction pada Megaproyek di Indonesia

Qualitatively, according to the waste in the construction sector in Indonesia, it is quite large, namely 57% when compared to the manufacturing industry which has 26% waste, the inefficiency in megaprojects is caused, among others, by too many design changes, low work expertise, delays in decision making, coordination that is not good between the parties involved, weak planning and control, delays in material delivery, and inappropriate work methods. Lean construction concept is used to eliminate waste and maximize value for users or customers. In addition, he said that the framework is a step-by-step guide in the form of a suitable guide to facilitate the implementation of the lean construction concept because the lean construction concept is a process-based concept. The purpose of this study is to identify critical factors that support and hinder the implementation of the lean construction concept in mega projects in Indonesia. In this study, a systematic literature review was used to examine the supporting factors and inhibiting factors for the implementation of lean construction. After conducting a literature review, four main supporting factors were obtained, namely managerial, labor, organizational and external. The managerial sub-factors are management commitment and Leadership Management. In addition, it was also found that the barrier factors from the implementation of lean construction were managerial, workforce, company/project organization and external. The supporting sub-factors of managerial are management commitment, management leadership, Management is unable to change existing construction concepts, Lack of training for contractors and subcontractors, misconceptions about lean construction method

Developing and validating high-value patient digital follow-up services: a pilot study in cardiac surgery

BackgroundThe existing digital healthcare solutions demand a service development approach that assesses needs, experience, and outcomes, to develop high-value digital healthcare services. The objective of this study was to develop a digital transformation of the patients’ follow-up service after cardiac surgery, based on a remote patient monitoring service that would respond to the real context challenges.MethodsThe study followed the Design Science Research methodology framework and incorporated concepts from the Lean startup method to start designing a minimal viable product (MVP) from the available resources. The service was implemented in a pilot study with 29 patients in 4 iterative develop-test-learn cycles, with the engagement of developers, researchers, clinical teams, and patients.ResultsPatients reported outcomes daily for 30 days after surgery through Internet-of-Things (IoT) devices and a mobile app. The service’s evaluation considered experience, feasibility, and effectiveness. It generated high satisfaction and high adherence among users, fewer readmissions, with an average of 7 ± 4.5 clinical actions per patient, primarily due to abnormal systolic blood pressure or wound-related issues.ConclusionsWe propose a 6-step methodology to design and validate a high-value digital health care service based on collaborative learning, real-time development, iterative testing, and value assessment.

Beyond nursing programming: preventing adverse events in patients with implantable cardiac devices undergoing invasive procedures and MRI after lean healthcare method

Abstract Funding Acknowledgements Type of funding sources: None. Introduction Follow-up in patients with cardiovascular implantable electronic devices (CIED) is essential to avoid adverse events and complications, such as arrhythmias, device dysfunction, and infections, among other events. Prevention plays a fundamental role, especially when these patients undergo non-cardiological invasive tests and/or procedures (e.g., surgeries) or magnetic resonance imaging (MRI). These situations sometimes require the reprogramming of the device. In our Arrhythmia's Unit, after developing a healthcare management model based on the Lean methodology, 2 processes were identified that implied a reduction in activity, a threat to efficiency and a risk to patients who would undergo invasive non-cardiological procedures or MRI. One of them was a significant number of "urgent" consultations and calls to evaluate and/or reprogram CIED in patients that underwent invasive non-cardiological procedures the same day, many of them without indication of reprogramming according to the type of procedure. Another one was the increase in consultations of people with CIED who require MRI, was often contraindicated because it produces adverse effects on the patient and/or device. Objectives: To implement action protocols, depending on the type of device and dependant on stimulation, for patients with CIED who undergo surgery and invasive non-cardiac procedures and MRI. To evaluate the number of urgent calls and adverse events before and after implementation. Methods: A single-centre, not randomized study has been designed. A year before and after the implementation of the protocol the following variables were quantified a) number of urgent calls b) number of adverse events (persistence of the special programming of the device more than 24 h after the end of the procedure: asynchronous stimulation, ICD therapies off, CIED dysfunction or unnecessary programming). Two protocols were developed: a) management of CIED carriers undergoing invasive non-cardiological procedures according to recent clinical practice guidelines. b) risk of dysfunction after MRI based on type/compatibility with MRI of the device, implanted leads, and stimulation dependence, using a colour scale, from safe (in green) to high risk of dysfunction (in black) Pictures 1,2. The protocols for action in the anaesthesia and radiology services were disseminated through sessions given by the arrhythmia unit staff. Results: In the year prior to implementing the protocol, 185 urgent calls/year were quantified, (15.1 calls/month) and the number of adverse events was 4 (0.2 events/month). One year after the implementation of the protocol, urgent calls were reduced to 4calls/year, representing 0.33 calls/month (p <0.001) and there was an absence of adverse events (zero events/month). Conclusions. The implementation of protocols based on recent clinical practice guidelines can reduce urgent calls and adverse events related to reprogramming in our centre, thus increasing patient safety.

Implementasi Lean Manufacturing untuk Mengurangi Waste pada Produksi Pivot Piece (Studi Kasus PT. Tri Jaya Teknik Karawang)

<p><em>PT Tri Jaya Teknik Karawang is one of the manufacturing companies engaged in the production of vehicle parts, because its main product is pivot piece. As for other forms of products produced by this company, such as Gongsol and Fuji Seat. This product research at PT Tri Jaya Teknik Karawang will be carried out on one type of Piece Pivot product, because this product is the company's main product, whose regular demand every month is always there and the amount is uncertain. This company has waste in the production line, namely the existence of product defects and lead times. This study aims to determine the types of waste and what factors occur in the production of pivot pieces at PT. Tri Jaya Engineering Karawang. By using the Lean Manufacturing method which begins with creating a Value Stream Mapping (VSM) then performs an analysis using the Failure Mode and Effects Analysis (FMEA) method. It is known that in the production of pivot pieces there are 3 types of waste identified, namely waiting time, unnecessary waste of inventory, and product defects. Proposed improvements to minimize waste in the production of pivot pieces are to carry out regular machine maintenance, create a production flow and provide warnings and evaluations of the performance of production operators.</em></p>

Research on improvement of vacuum pump production system based on value stream analysis

Abstract In this paper, H company vacuum pump V8 products as the research object, combined with lean production theory and value stream diagram analysis method to identify the key waste problems in the production system; and from the production line balance, facility layout optimization, work in process inventory lean and other aspects of the improvement plan; finally, using Flexsim simulation software to verify the feasibility of the scheme. After improvement, the balance rate of vacuum pump V8 product line is increased by 21.96%, the production cycle is shortened by 36.62%, and the value-added ratio is increased by 51.89%. The practical application shows that the use of value stream diagram analysis technology can help to improve the balance rate of production line, shorten the production cycle, and make enterprises achieve lean production.