Lean Paradigm Research Articles

On the adoption of lean manufacturing principles in process industries

Traditionally, the lean paradigm has been applied to discrete manufacturing of items that can be easily put together and taken apart. The process industry, on the other hand, transforms raw materials into cohesive units that are basically blended into a final product with parts that cannot be disassembled and then reassembled. The current lean literature provides numerous commendable examples of theory and practices of lean principles in discrete manufacturing. However, its application in process industry is limited. Furthermore, there is no systematic accounting of the lean literature in this sector, which may have contributed to lesser awareness in the industry. This paper provides a state-of-the-art review of lean manufacturing literature with respect to its applications in process industry. It contributes to the classification of literature in a manner which helps to identify strategies suitable for the adoption of lean concepts in process industry. The paper seeks to synthesise the literature with an emphasis on identifying the scope for lean in process industry and associated benefits. The review also presents an analysis of the lean tools and techniques that have been applied or have potential application in the process industry and the challenges to implement lean. We believe that such a comprehensive review will not only facilitate the adoption of lean in process industry but will also provide agenda for further research by exposing voids in the knowledge base.

A Lean Based Overview on Sustainability of Printed Circuit Board Production Assembly

With increasing the sustainability awareness, the goods that ends up with generating hazardous waste in dumps and landfills, are more discussed environmentally, socially, and economically. Printed Circuit Boards (PCBs), which form the basis of the high quality electronics product, are complicated to be produced due to the diversity of materials and components, and technologically waste of hazardous disposal due to the difficulty of a concrete recycling process. Thus, a sustainable life cycle of printed circuit boards requires a definite highlight of the material selection legislation, environmental burdens of the manufacturing process, and disposing and recycling process.This article presents an overview on sustainability issues with Lean paradigm perspective in PCB assembly and resource consumption showing their structure and materials, legislation issues on material and production, and the alternative solutions for the recent green innovations and production of PCBs.

An integrated fuzzy QFD and TOPSIS approach to enhance leanness in supply chain

Lean principles are currently adopted in supply chain to ensure competitiveness in the global market and to meet customer requirements. This lean paradigm focuses on cost reduction using various tools and philosophies like just in time (JIT) and total quality management (TQM). To be lean, a supply chain must ensure many distinguishing lean attributes (LAs) influenced by lean enablers (LEs). In this paper, an integrated technique for order preference by similarity to ideal solution (TOPSIS) and quality function deployment (QFD) approach is proposed to increase the leanness of supply chain. The objective is to identify the most viable LEs to achieve the required LAs. Due to impreciseness and vagueness associated with decision-making problems, fuzzy logic is used to deal with linguistic judgments expressing relationships and correlations required by QFD. Presentation of a case study from the Indian food processing industry illustrates the proposed methodology.

Developing a Lean Supply Chain Performance Framework in a SME: A Perspective Based on the Balanced Scorecard

To keep ahead of the completion, organizations look for continuous improvement in Supply Chain Management (SCM). Lean paradigm connected to SCM is a strategy based on cost and time reduction to improve the effectiveness. At the operational level, Lean Supply Chain (LSC) is focused on optimizing the processes of all supply chain, searching for simplification, reducing waste and reducing activities that do not add value. A well-defined lean supply chain measurement system increases the chance for success because it enables managers to see areas where supply chain performance can be improved, so they can focus their attention, and obtain higher levels of performance. There are a number of conceptual frameworks and discussions on supply chain performance measurements in the literature, however there is a lack of empirical analysis and case studies on performance metrics and measurements in the supply chain environment of Small and Medium Sized Enterprises (SMEs). This research aims to develop a conceptual framework for managing LSC, integrating both financial and non-financial performance dimensions and so it expands the existent knowledge and provides indication of how LSC performance can be assessed and improved in this and other kinds of organizations. The proposed framework has been implemented in a Portuguese SME operating in the food manufacturing sector. A case study was developed to better understand the suitability of this tool.

Empirically Investigating a Hybrid Lean-Agile Design Paradigm for Mobile Robots

AbstractLean design and agile design paradigms have been proposed for designing robots; yet, none of them could strike a balance between cost-effectiveness and short duration of the design process without compromising the quality of performance. The present article identifies the key determinants of the mobile robots development process. It also identifies empirically the mobile robot design activities and strategies with the most influence on mobile robot performance. The study identified statistically the mobile robot design activities and strategies most positively correlated with mobile robot performance. The results showed that 65% of typical mobile robot design activities and strategies are affiliated with the lean design paradigm, while the remaining 35% are affiliated with the agile design paradigm. In addition, it was found that 22% of the lean mobile robot design activities and strategies and 25% of the agile mobile robot design activities and strategies, significantly with 99% confidence, are among the design activities and strategies most positively correlated with improving mobile robot performance. A hybrid lean-agile design paradigm is thus proposed.

Design and implementation of a Drum-Buffer-Rope pull-system

Purpose: This paper investigates the selection, design and implementation of a Drum-Buffer-Rope (DBR) type of production pull-system in a panel fabrication plant characterised by extensive shared, batch resource resources within a low volume UK manufacturer of large vehicles. This was the second of a series of two related research projects conducted under the aegis of a Lean initiative at this case firm.Design/methodology/approach: A purposively selected longitudinal case study conducted over 24 months and organised around a two phase research design. The initial body of evidence included a detailed map constructed by a project team of eight managers and accountants during a two day structured workshop; numerous unstructured interviews and observation of shop floor practices; document and archival analysis, and 140 photographs of the focal operation. Supplemented by extensive financial and operational data extracted from the firm’s accounting and MRP systems, including all data necessary to construct and implement bespoke capacity planning, work in progress (WIP) monitoring and simulation modelling tools. The case firm is anonymised.Findings: The Lean manufacturing literature ignores the real-world issue of shared resources, and this gap is attributable to the concept of ‘rightsizing’ tools and equipment that is widely promoted within the Lean community. The case panel plant is characterised by extensive shared resources; many of which are also batch processes. The most appropriate pull-system method for this production environment is DBR. The detailed design of the DBR mechanism required a controlled transfer buffer of overhead conveyance capacity after the Drum because the extent of downstream process variability risked it being unable to offload panels, hence compromising throughput.Research limitations/implications: The study is based upon a single case. This consequently has implications for the ability to generalise from the results.Practical Implications: When the DBR pull-system design was implemented it reduced the number of panels in WIP by 60%. This equated to a 56% (18 days worth) reduction of manufacturing lead time and more than doubled the plant’s inventory turns (from 9.1 to 21.2). It also significantly improved delivery schedule adherence, with downstream jig stoppages in the Final Assembly falling from an average of six to less than one per week. The financial benefit was independently audited to equate to an annualised value of $850 K. Consequently, this project was awarded the first prize at its parent enterprise’s annual worldwide process improvement competition.Originality/value: This paper details a novel technique that permits the routings of multiple value streams to be mapped and is useful for highlighting the identity and location of shared resources. It also contributes significantly to the literature that is available on the relationship between the Lean paradigm and the management of shared production resources, and adds to the literature on the detailed design and implementation of a DBR pull-system in a jobbing-type of environment.

Lean implementation through value stream mapping: a case study in an Indian pump manufacturing company

During the past two decades, the tools and techniques of lean manufacturing paradigm are increasingly being implemented in organisations globally. The scattered implementation of these tools and techniques has been preventing the organisations from effectively reaping the benefits of lean manufacturing paradigm. Meanwhile, a few researchers have found out that the initiation of lean manufacturing paradigm will result in leanness if it is begun by implementing value stream mapping (VSM) technique. In order to examine this finding, in this research paper, a case study on implementing VSM as the lean manufacturing initiative is reported. During the conduct of this case study, VSM was applied in an Indian pump manufacturing company. The experiences of conducting this case study have revealed that, VSM has the capability to implement the lean manufacturing tools and techniques tactfully for matching production lead time with takt time. This capability will enable the companies to achieve profitability and competitive strength.

A model to assess the lean capabilities of automotive industries

Changing customer and technological requirements force manufactures to develop lean capabilities. Many organisations have adopted lean thinking paradigm in their drive to optimise performance and improve competitive position. In this paper, the application of lean production systems is described in an automotive context. The results reported are based on the data collected from a survey covering around 15 manufacturing companies in India using a standard questionnaire. The study was driven by a conceptual model which relates lean practices to competitive objectives. The method of analytic hierarchy process (AHP) was used to analyse and identify which among the various lean production tools and enablers are likely to have greater impact on realising a lean production system.

RFID for the extended lean enterprise

PurposeIn the traditional sense, information technology has often been viewed as a contributor to waste within lean production. However, as the business world changes and competition from low‐cost countries increases, new models must be developed which deliver competitive advantage by combining contemporary technological advances with the lean paradigm. The purpose of this paper is therefore to contribute within this area, and it aims to evaluate the supporting role of radio frequency identification (RFID) technology in the context of lean thinking. The paper also aims to consider the application of RFID in order to revolutionize the lean paradigm, and to propose a framework for the use of RFID in order to create the extended lean enterprise, which the authors suggest can improve the competitiveness of manufacturing supply chains.Design/methodology/approachThe paper's applied research methodology is case study. Having first explored the relevant literature surrounding the topic, the paper presents a conceptual framework for the role of RFID in the extended lean enterprise, and apply the framework to two practical case studies. Data were primarily collected through semi‐structured interviews with key contacts within the companies. For triangulation, the authors also made use of direct observations and company documentation.FindingsThe paper operationalizes the five lean principles with practical examples in the context of RFID in the extended lean enterprise. It uses the results to propose a conceptual framework for the role of RFID in the extended lean enterprise, which can be used by researchers and practitioners to better integrate information technology such as RFID in the lean paradigm. The case studies provide good practical examples of the applications and implications of RFID in the extended lean enterprise, with theoretically grounded insights. Such a concept appears very little in current academic literature. The findings suggest that RFID technologies are a key enabler in the development and further support of the extended lean enterprise.Originality/valueWithin the field of lean production and information technology, there has been a continuous debate as to whether both approaches are complimentary or contradictory. Therefore, this paper fulfils an identified need to study the interactions between a modern example of information technology (RFID) and its role within lean production, making a valid contribution within this field of research.

Lean supply chain strategy and integration: their impact on product innovation and product quality

The lean paradigm has extended beyond the internal activities of the firm to encompass those of supply chain partners but empirical testing of the alignment of a lean supply chain strategy and inte...

Managing Concurrency in Systems Engineering

AbstractThe engineering of complex products and services cannot be performed without iterations. Products and services with a multi‐level system architecture and a reasonable number of system elements usually show development activities on individual system elements performed in parallel. The development of each system element is widely managed independently. This paper is concerned with managing concurrency resulting from both, the iterative nature of systems engineering per se, and the multiple projects for developing all the system elements.Lean systems engineering is promising improvements to the systems engineering process in general. However, lean systems engineering is still evolving. Particularly, the integration with all other system life cycle processes needs to be progressed without compromising the lean paradigm. In this paper, amendments to the current state of lean systems engineering are proposed in order to close some of the gaps.

State-of-the-art of ‘Lean’ in the aviation maintenance, repair, and overhaul industry

The increasing need for maintenance, repair, and overhaul (MRO) organizations to meet customers’ demands in quality and reduced lead times is key to its survival within the aviation industry. Furthermore, with the unpredictability in the global market and difficulties with forecasting characteristic of the MRO industry there is an increased need for the re-evaluation of the operation models of organizations within this sector. However, severe economic turmoil and ever-increasing global competition introduce the opportunity for the adoption of a resilient, tried, and tested business operation model such as ‘Lean’. In order to understand this concept, its long-term viability, and its application within the aerospace MRO sector fully, this paper presents the state-of-the-art in terms of the adoption of Lean within the MRO industry by carrying out a systematic review of the literature. This paper establishes the common perception of Lean by the MRO industry and the measurable progress that has been made on the subject. Some issues and challenges are also highlighted including the misconceptions that arise from the direct transference of the perception of Lean from other industrial sectors into the aerospace MRO industry. The ‘enablers and inhibitors’ of Lean within the aviation industry are also discussed. This paper exposes the scarcity of the literature and the general lagging behind of the industry to the adoption of the Lean paradigm and thus highlights areas where further research is required.

A new lean paradigm in higher education: a case study

PurposeThis case study aims to demonstrate that lean principles and practices utilized in industry can be successfully applied to improve higher education administrative processes through an innovative and engaging learning experience involving undergraduate students.Design/methodology/approachThis is a first‐hand account by the instructor of a small group of undergraduate students in a seminar course working as a team to identify waste and redesign the university's grade change administrative process.FindingsThis case study found that a small group of undergraduate students can quickly learn basic lean principles, tools and practices, and reinforce that learning by applying them in a team effort to significantly improve a university administrative process.Practical implicationsWith the changing higher education environment, where efficiency and effectiveness have become more imperative due to increasing budget constraints and competition for students, this case study shows that students can play a major role in the improvement of university administrative processes while at the same time gaining new knowledge and skills that are highly valued in industry.Originality/valueThis case study confirms an opportunity for universities to create a valuable learning experience for their undergraduate students, by involving them in improving the administrative processes of the university.

Development of Lean Model for House Construction Using Value Stream Mapping

Lean construction has recently attracted considerable attention in the home building industry. Lengthy delivery time and significant waste in the construction process have caused many home builders to seek a more effective production model that will increase process reliability, reduce total lead time, and improve quality. However, although housing construction provides the closest analogy to manufacturing, a high level of variability prevents the direct transplantation of lean paradigm and techniques. In collaboration with a local home builder, a systematic approach based on value stream mapping technique is developed in this research to analyze the current process and to formulate a lean production model. The model has four main features: synchronized first-in, first-out lane-based flow, production leveling at pacemaker, work restructuring, and improved operation reliability. A simulation template is built to verify the model and to assist in the development of interim implementation models. This paper presents data collection and value stream selection, current practice analysis, and specific changes proposed for the lean production model.

Value chain analysis in the UK beef foodservice sector

Purpose – The purpose of this article is to discuss the results from a UK government‐funded applied research programme on value chain analysis that examined the beef foodservice sector. The demands and dynamics of this sector differ markedly from those of the supermarket, which is the dominant channel for beef produce and which forms the focus of the existing literature. This is a challenging environment for the application of collaborative supply chain improvement principles because of its high level of regulatory control, power relationships and low profit margins. Design/methodology/approach – This is an applied research project that was case study based and employed the value chain analysis method. Empirical work was conducted over an 11‐month period and included a one‐week whole‐team study tour to Argentina. Informants encompassed UK and Argentine livestock producers, an Argentine meat processor, a UK meat import operation, a UK meat processor, a UK foodservice distribution centre and two foodservice restaurants. Findings – The paper concentrates on the key findings pertinent to the upstream members of the above chain. It highlights specific supply chain waste elimination opportunities at both producer and processor level. It also establishes valuable learning points for the UK beef industry as a whole. Originality/value – This study represents the first holistic and non‐partisan study of its type within the UK beef industry. This paper adds to the limited body of knowledge on supply chain management within the foodservice sector. It also provides the first explanation and analysis of its kind on supply chain operations within the Argentine beef industry. It quantifies the magnitude and nature of the cost advantage afforded the Argentine producer over its best practice counterpart. Finally, it presents a number of reflections upon the implications of this study for the concept of best practice and also the Lean paradigm.

The lean production paradigm and the influence of automakers in the industrial organisation of their suppliers: the case of the Brazilian automotive complex

This paper provides a multiple case study of the Brazilian automotive and auto parts industries and an analysis of the trends in their organisations and relationships. After a period following the international standards in work organisation and supply chain relationships, transnational automotive companies developed new models to improve their production competitiveness. In these lean models, suppliers have an important role throughout the automotive chain. The target is to answer this question: does the relationship with automotive parts companies help auto parts companies to adequate themselves to lean production principles? It is done through a multiple case study because the phenomenon that is studied is very complex and cannot be taken out of context without losing its consistency. Taking into account the methodological aspects, the present study was based on a multiple case study that was conducted in six average-sized companies to analyse their relationships with their automotive clients.

Implementation of lean initiatives to minimise defects in a forging enterprise

This research addresses the implementation of the lean philosophy in a forging environment where hot forging operations are performed. In this paper, the authors have kept their prime focus on reducing various forging defects such as under-filling, overlap, etc. in the connecting rod production flow line. After giving a brief on the lean paradigm, a systematic approach is suggested for the implementation of the lean manufacturing principles. An analysis of the various critical process parameters has been carried out with the help of Taguchi's method of Design of Experiment (DOE). To save time and to make the analysis more precise and cost effective, a simulation exercise using finite element analysis is also performed. Furthermore, the results obtained are tested on the shop floor and it is realised that the defect levels have reduced significantly. Future courses of improvement are recommended. Consequently, the idea of an automatic billet flow control mechanism between the furnace and the press with a temperature indicator is advocated.

Lean thinking in the UK red meat industry: A systems and contingency approach

Food Value Chain Analysis (FVCA) based on the lean paradigm is being applied to eight value chains in the UK red meat industry. This paper is based on the forth chain involving a value added pork for a major retailer. Systems theory is used to evaluate FVCA based on four sub-systems—goals and values, logistics, human resources and management structure. The results show a positive potential logistics benefits along the chain, but identified two key implementation issues; inter-company alignment of other sub-systems and chain organisational stability through time.

Value chain analysis in consumer focus improvement

PurposeA key vision of tomorrow's industry is creating supply chains which collaboratively strive on enhancing the value to the end‐consumer. The purpose of this paper is to introduce the food value chain analysis (FVCA) methodology for improving consumer focus in the agri‐food sector based on the lean paradigm, value stream mapping and value chain analysis (Porter, 1985).Design/methodology/approachThis contribution presents a case‐study of a UK red meat supply chain explaining how the FVCA method enabled a team of researchers and practitioners to identify the misalignments of both product attributes and supply chain activities with the consumer needs.FindingsThis paper explains how the FVCA methodology potentially realigned the processes along the supply chain with the true consumer requirements and why the supply chain effectiveness was improved; this follows with a description of the subsequent efficiency gains from application of the FVCA methodology.Originality/valueThis paper further defines the demarcation between supply chain “effectiveness” and “efficiency”. This paper contributes to the debate on the importance of supply chain effectiveness by linking to consumer value at every stage of the supply chain.

Application of lean paradigm in red meat processing

PurposeLean is a well‐established industrial paradigm and has proved to be of significant benefit in different sectors of the manufacturing industry (e.g. automotive and aerospace). This paper aims to report on the introduction of lean to a new sector – the “UK red meat industry”. It highlights the benefits of lean production in one specific manufacturing area, the “cutting room”, where meat is split down from a carcass into retail cuts of meat.Design/methodology/approachA multiple case study approach is adopted in this paper. As part of the Red Meat Industry Forum's Value Chain Analysis Initiative, five cutting plants are presented as case studies in this paper.FindingsThis paper identifies two “traditional” and three “advanced” cutting rooms and reports a typical 25 per cent productivity gap. The paper tentatively concludes this is due to the advanced cases practicing lean techniques, such as “Takt‐time” and “work standardization”.Originality/valueThe literature review identifies a gap in previous research on the applications of logistics and operations management concepts and practices into the red meat industry. Particularly, lean techniques have been overlooked in the red meat industry.