Lean Production System Research Articles

Job rotation scheduling in the Seru system: shake enforced invasive weed optimization approach

PurposeLine–cell conversion and rotation of operators between cells are common in lean production systems. Thus, the purpose of this study is to provide an integrated look at these two practices through integrating job rotation scheduling and line-cell conversion problems, as well as investigating the effect of rotation frequency on flow time of a Seru system.Design/methodology/approachFirst, a nonlinear integer programming model of job rotation scheduling problem and line–cell conversion problem (Seru-JRSP) was presented. Then, because Seru-JRSP is NP-hard, an efficient and effective invasive weed optimization (IWO) algorithm was developed. Exploration process of IWO was enhanced by enforcing two shake mechanisms.FindingsComputations of various sample problems showed shorter flow time and less number of assigned operators in a Seru system scheduled through job rotation. Also, nonlinear behavior of flow time versus number of rotation periods was shown. It was demonstrated that, setting number of rotation frequency to one in line with the literature leads to inferior flow time. In addition, ability of developed algorithm to generate clusters of equivalent solutions in terms of flow time was shown.Originality/valueIn this research, integration of job rotation scheduling and line–cell conversion problems was introduced, considering lack of an integrated look at these two practices in the literature. In addition, a new improved IWO equipped with shake enforcement was introduced.

Lean Manufacturing 4.0 of Polymeric Injection Molding Products

AbstractIn the polymeric products industry, the lean production system is perceived as a solution to reduce difficulties of manufacturing automation processes complexity while reducing used resources, eliminate losses, and increase efficiency, flexibility, and profitability. Industry 4.0 is the stage of intelligent automation that exploits the latest developments in polymeric products engineering. Through implementation of information technology and the Industry 4.0 concepts in lean manufacturing 4.0 of polymeric injection molding products is a challenge that needs a strategic approach to efficient interconnection processes. The main achievements of intelligent polymeric products manufacturing system are based on the versatility and individualization of designing and manufacturing processes. The transition from lean manufacturing to Lean 4.0 manufacturing system is a complex project that requires physical production system update, transforming lean tools, build the cyber production system, define and implement Lean 4.0 tools, and connecting them into a new integrated cyber–physical system. This paper presents a strategy for identifying the transition that can be approached within an intelligent and adaptive molding cell fabrication of polymeric products industry.

Implementing Lean Production Management System (LPMS) in the Practice of Russian Organizations

This paper is devoted to lean production management system (LPMS), which is being implemented into various productive and non-productive spheres, as well as used in education, medicine, banking, consulting and social sphere. The article considers the enterprises, which have implemented the lean production system and which are called Lean-enterprises. The stages of implementing LPMS in order to improve the efficiency of production and non-production sectors of the Russian Federation on the basis of Recommendations, developed by the Ministry of Industry and Trade of Russia, are presented. The practice of implementing LPMS in the activity of a nonprofit organization SAI BR MFC is shown; the expected effects of the LPMS implementation are revealed, such as: reduction of a service’s completion time; improving labor efficiency; improving the quality of customer satisfaction; increasing the number of applications, processed by windows of MFC; deepening the assimilation of LPMS methods and tools; increasing the market fluctuation tolerance of MFC.

A lean production system design for semiconductor crystal-ingot pulling manufacturing using hybrid Taguchi method and simulation optimization

PurposeThe purpose of this study is to propose an innovative methodology in solving the lean production design from semiconductor crystal-ingot pulling manufacturing which is an important industry. Due to the complexity of the system, it is computationally prohibited by an analytical approach; thus, simulation optimization is adopted for this study.Design/methodology/approachFour control factors that affect the system’s performance, including the pulling strategy, machine limitations, dispatching rules and batch-size control, are identified to generate the future-state value stream mapping. Taguchi two-step procedure and simulation optimization are used to determine the optimal parameter values for a robust system.FindingsThe proposed methodology improved the system performances by 6.42 and 12.02 per cent for service level and throughput, respectively.Research limitations/implicationsThis study does not investigate operations management issues such as setup reduction, demand forecasting and layout design.Practical implicationsA real-world crystal-ingot pulling manufacturing factory was used for the case study. The results are promising and are readily applied to other industrial applications.Social implicationsThe improved performances, service level and throughout rate, can result in an improved customer satisfaction level and a reduced resources consumption, respectively.Originality/valueThe proposed methodology innovatively solved a practical application and the results are promising.

Lean manufacturing: ações de melhorias em empresa metalmecânica

The current industrial scenario in Brazil stimulates competition among companies therefore, aiming at survival in the market and their potential growth, organizations are obliged to seek alternative tools and solutions. The Lean Production System (SPE) has received great attention worldwide due to the results obtained in large corporations with regard to waste reduction and cost reduction. In this context, the present work has the purpose of proposing the application of Tools of the Lean Production System (SPE), through the analysis of the production process of a metal-mechanic industry located in the state of Parana - PR, Brazil, and specialized in the production of a line of sprayers for agriculture. Based on the bibliographic research of the techniques and tools that structure the SPE, a case study is presented. The proposal of the tools to be applied was developed, according to the conditions found in the studied company. It proposed the implementation of the 5 S Program; the layout adaptation and the Rapid Change of Tools as premises for the subsequent implementation of other SPE tools. Some actions were initiated, bringing significant results to the company, as better organization of the sector, reduction of the productive lead time by 25% and reduction in setup time, improvement in production time, better organization, making it possible to standardize production orders.

The Impact of the Digital Transformation on Lean Production Systems

Lean Production Systems (LPS) are an enterprise-specific set of strategic goals and principles in combination with operative methods and tools for the holistic management of production processes. Since LPS such as the Toyota Production System have been successfully established in many companies during the past decades, they are nowadays challenged by digital transformation, especially on the level of methods and tools. Therefore, this paper gives a literature review on digital transformation and LPS. As a result, main indicators for digitally driven change within LPS are identified.

4th Industrial Revolution Design Through Lean Foundation

Industry 4.0 was introduced with the hope of transitioning to the next industrial revolution. I4.0 is a vision of increasing flexibility and efficiency within a system of low complexity. Despite this intention, Industry 4.0 has required users to understand complex information and communication systems, limiting usability and therefore not necessarily satisfying the original vision. However, application of principles from the Lean Production Systems originally developed in the 1930’s in combination with Industry 4.0, may help to reach its desired goals. Through a literature review, this paper discusses the current state of art of Industry 4.0 and some Lean Production Systems principles. The paper focuses on a model combining Lean Production Systems with Industry 4.0, that was created in response to the shortcomings of the anticipated industrial revolution. With a Lean Production System as a foundation, the six design principles of I4.0 of interoperability, virtualization, decentralization, real-time capability, service orientation, and modularity can be better implemented to reach the vision of highly flexible and low complexity systems. In return, horizontal and vertical integration within Industry 4.0 can support and accelerate Lean principles by reducing human error and increasing intercommunications between the systems, resulting in a productive integration. The specific principles of Lean that could boost Industry 4.0 will be discussed, demonstrating why a company should be Lean, meaning value adding processes and stakeholder orientation are at its core.

Change management practices to support the implementation of lean production systems: a survey of the scientific literature

Abstract: The transition from mass production system to lean production system carrier significant changes in operational strategies of industrial organizations. A production model system can engender different reactions by the people involved; some of them can show resistance during the process, ranging from unreserved support to a hidden resistance (even explicit). In order to identify the main practices to support change processes, this study provides a literature review to systematize the main researches related to change management during lean manufacturing implementation. This study aims to provide a systematic literature review covering main researches related to change management and lean manufacturing implementation to identify the main factors that affect the production system change. The research was carried out between October 2016 and January 2018. In methodological terms, literature review was developed by using Scopus and ISI web of Science publications. As a result of this study, 25 papers related to lean manufacturing implementation were identified and 10 factors were consolidated. The most relevant practices of change management were also identified to support lean production system implementation.

Ergonomic intervention combined with an occupational and organizational psychology and sociology perspectives in production systems

The paper describes a propose interdisciplinary approach for improving working conditions in production systems. The proposed approach has been customized and apply in the case of a lean production system in order to demonstrate its efficiency and effectiveness. The research approach and its associated methodology consists of three stages: (1) a qualitative research using the Grounded Theory, which provide a theoretical model on the the employees behavior within the analyzed lean production system; (2) a quantitative research, survey based on a designed questionnaire, for the investigation of the motivation – satisfaction relation; (3) a quantitative research for the ergonomic risk assessment associated with repetitive upper limb movements (that are dominant in the case of the assembly line that has been studied) using the OCRA method for the improvement of the workers stress. The research results contribute to the knowledge development and to the the diminishing of the occupational hazards and generating workplace wellbeing.

Designing a Strategic Model to Adapt Lean Production System for Toyota Company of Higher Education in Iraq and Measuring Its Impact on University Learning

The idea of the current research is based on the possibility of developing the quality of the higher education environment by adapting the concern of “value-oriented production” which depends on removing activities that hinder the teaching, student and administrative performance in Iraqi universities. The research aims to rethink the improvement of added value based on the concept of lean production through a main hypothesis, “There is a possibility to adapt the lean production system model for Toyota company or (T.P.S.M) to the higher education environment.” The research has reached some of the most important conclusions, “It is possible to use the lean production system according to Toyota to improve the quality of Higher education in Iraq.”

Повышение конкурентоспособности рыбохозяйственного комплекса через реализацию стратегии развития

The article deals with the issues of increasing the competitiveness of the fisheries complex of the Russian Federation as the most important direction in the implementation of the country’s food security. Improving competitiveness requires systemic changes in the production chains of the fishing industry through the introduction of a lean production system. Management according to its principles allows you to transform your business, focus on innovation, and saturate the food market with fish and seafood in accordance with consumer demand. In the organization of a fishing business under the lean production system, the starting point is to determine the value of fish and seafood for the consumer, and the main goal of all participants in the production chain is the desire to meet consumer demand with the created value. This goal setting forces the organization’s management along the chain to identify shortcomings and losses, improve technologies, and reduce unproductive costs.

Construction with digital twin information systems

AbstractThe concept of a “digital twin” as a model for data-driven management and control of physical systems has emerged over the past decade in the domains of manufacturing, production, and operations. In the context of buildings and civil infrastructure, the notion of a digital twin remains ill-defined, with little or no consensus among researchers and practitioners of the ways in which digital twin processes and data-centric technologies can support design and construction. This paper builds on existing concepts of Building Information Modeling (BIM), lean project production systems, automated data acquisition from construction sites and supply chains, and artificial intelligence to formulate a mode of construction that applies digital twin information systems to achieve closed loop control systems. It contributes a set of four core information and control concepts for digital twin construction (DTC), which define the dimensions of the conceptual space for the information used in DTC workflows. Working from the core concepts, we propose a DTC information system workflow—including information stores, information processing functions, and monitoring technologies—according to three concentric control workflow cycles. DTC should be viewed as a comprehensive mode of construction that prioritizes closing the control loops rather than an extension of BIM tools integrated with sensing and monitoring technologies.

Development of lean production system using value stream mapping approach: a case study

Intense competition in global market is encouraging management to search for new ways to reduce cost and improve profits. Manufacturing firms are realising that cost reduction through waste elimination can improve their competitive potential. Lean production concepts can be employed for waste elimination. However, managers find it difficult to identify the key areas for waste elimination. The field of lean production has offered value stream mapping (VSM) as a visualisation tool to identify waste elimination opportunities. Using this tool, it is possible to map the current state and accordingly analyse for achieving waste elimination. In order to illustrate this aspect, the case study presented in this paper shows the way the firms can apply VSM for identifying the potential areas for applying this waste elimination technique. The purpose of this research is to examine value stream mapping (VSM) implementation in a gear manufacturing company located in national capital region of India. The case study shows that the production time, inventory and defects can be reduced significantly. Thus, VSM assists the managers to envisage the current level of wastes occurring in an organisation and the future means of eliminating them.

Function framework for describing digital technologies in the context of lean production

Intensifying challenges such as volatility, individualization and consequential complexity increasingly bring lean production systems to their performance limits. Using digital technologies serves as possible solution to overcome the limits of lean production and to enhance its capability of reducing waste within production processes. Therefore, a holistic and generic approach is required that allows to characterize digital technologies with respect to their effects on reducing waste in production processes. This paper introduces a function framework that describes digital technologies based on a function-oriented and impact-driven attribution concerning their effects on reducing waste and therefore on superordinate goals of lean production.

ПРОЕКТНЫЙ ПОДХОД К УПРАВЛЕНИЮ ВНЕДРЕНИЕМ БЕРЕЖЛИВОГО ПРОИЗВОДСТВА

The article highlights methodical approaches to building a mechanism for effective management of the implementation of the lean production, as a factor in solving the problem of Russia's lag behind developed countries in productivity. The issues related to differences in the ideology of Japanese, American and Russian lean production systems, analysis of historical experience of implementation, trends and effectiveness of var-ious management options for the implementation of lean production are considered for Russia and developed countries; the reasons for the lack of efficiency of implementation in the dynamics are considered; An assess-ment of expected performance under the national project «Productivity and employment support”; methodical recommendations have been proposed to form an effective mechanism for implementing lean production based on a combination of project management and quality management.

A Study of Driving Factors and Barriers of Lean Production Systems

A Study of Driving Factors and Barriers of Lean Production Systems

Techniques and tools of lean production: multiple case studies in brazilian agribusiness units

Abstract The literature regarding Lean Production philosophy is vast depicting historical aspects, implementation challenges, benefits of its adoption and other topics applied to various industries and services. However, the agribusiness segment, one of the major segments of the global economy features a large gap in national and international literature. This article aims to conduct a research through multiple case studies concerning the use of techniques and tools of Lean Production System in agribusiness organizations. Multiple type case studies were conducted in eight agribusiness units from different segments through the application of structured interviews, on site visits and document analysis. The research carried has identified that Lean Production techniques and tools are applicable to agribusiness environments, and that the ones which involve improvements in process control, production flow and logistics have higher emphasis on research units. Techniques and tools such as long-term supplier and customer relationship, production smoothing/heijunka and value stream mapping distinguished themselves by the similarity of use when compared to previous studies in agribusiness environment. It was also identified that there are differences concerning the adoption of the techniques and tools in research units that operate in production environments of the type Make to Order or Make to Stock. Such differences are imposed by specificities that affect agribusiness organizations, which is indicative for future studies.

Addressing Issues of Amoeba Management by Introducing Lean Production System:

Addressing Issues of Amoeba Management by Introducing Lean Production System:

Assessment of hypothetical correlation between the various critical factors for lean systems in automobile industries

Lean production system leads to the elimination of non value added activities in the industrial environment and restructure the existing production procedures and processes to achieve improvements in terms of cost reduction, increase in quality and profit. The purpose of this paper is to identify the critical factors of lean Implementation and to evaluate their role of critical factors in organizational performance. The following factors are considered to measure the impact of lean system such as business type, period of usage of lean, type of benefits achieved from lean, lean activity occurrence, turnover rate, Employee training, customer satisfaction percentage, lean activity interval, the delivery defect rate in Indian automobile industries. To achieve these objectives a empirical study was conducted through 83 copies of questionnaire which is circulated to various employees attended the manufacturing exhibition in India. Frequency analysis is carried out for eight critical factors for lean implementation. The cross tabulation is charted out in order to find the hypothetical relations between the various factors. Each factor influences the lean production success, which is proved using the hypothesis testing. Hypothetical findings based on the survey reveal that successful lean implementation can positively affect both employees and industrial performance in Indian automobile industries.

Development of lean production system using value stream mapping approach: a case study

Intense competition in global market is encouraging management to search for new ways to reduce cost and improve profits. Manufacturing firms are realising that cost reduction through waste elimination can improve their competitive potential. Lean production concepts can be employed for waste elimination. However, managers find it difficult to identify the key areas for waste elimination. The field of lean production has offered value stream mapping (VSM) as a visualisation tool to identify waste elimination opportunities. Using this tool, it is possible to map the current state and accordingly analyse for achieving waste elimination. In order to illustrate this aspect, the case study presented in this paper shows the way the firms can apply VSM for identifying the potential areas for applying this waste elimination technique. The purpose of this research is to examine value stream mapping (VSM) implementation in a gear manufacturing company located in national capital region of India. The case study shows that the production time, inventory and defects can be reduced significantly. Thus, VSM assists the managers to envisage the current level of wastes occurring in an organisation and the future means of eliminating them.