Lean Tools Research Articles

A visual management and augmented-reality-based training module for the enhancement of short and long-term procedural knowledge retention in complex machinery setup

Proper training for operators is essential, given the complexity of modern manufacturing and the challenges posed by diverse worker demographics and high workforce turnover. Since conventional training methods are inadequate when considering the mentioned challenges, digital technologies and assistive devices can be used to improve information management. This work studies how the combination of Augmented Reality (AR) and Visual Management (VM) supports worker training by considering short- and long-term efficacy. The literature gaps on researching the training and knowledge retention of manufacturing workers using combined lean tools and digital technologies indicate that current studies focus on short-term training performed in laboratories, overlooking the integration of VM and AR for industrial training. Thus, the authors developed and validated in practice a VMAR-based training module for the setup of complex machinery in the process industry. To assess its efficacy, a comparison between a test group and a confirmation group of company’s workers has been performed. The number and types of setup error have been collected and analysed to evaluate and compare short- and long-term procedural knowledge retention. The results reveal that the VMAR-based training module better supports workers both in the short- and long-period compared with traditional working procedures. Furthermore, the analysis demonstrates the inefficacy of traditional approaches in properly supporting the training of complex machinery setups considering the study’s application. Future works should address the assessment of knowledge retention by considering a longer period, as well as on physiological data collection to better understand which elements of the training module are most crucial to the transfer of knowledge.

Can industry 4.0 work together with lean? An investigation from Malaysian lean manufacturing sector

An examination of Industry 4.0 (I4.0) and its impact on lean manufacturing (LM) is not yet detailed, properly evaluated or validated. Notably, there is a lack of recent studies that evaluated I4.0 technology mapping and prioritization in the LM industrial context in Malaysia. The study aims to evaluate how I4.0 technology enablers influence the use of lean tools. Moreover, this study evaluates the correlation between company type and I4.0 implementation maturity, familiarity, and sources exhibiting an inclination to advance skills. The study evaluated 208 respondents belonging to several LM enterprises in Malaysia. Self-administered questionnaires were used and association analysis, based on the independence test, was used to assess the consensus based on the devised hypothesis. The outcomes were obtained using correspondence assessment of the asymptotic significant correlation coefficient (p) in which to draw conclusions using the p determined during hypothesis evaluation, a 0.05 significance level indicates all null hypotheses must be accepted. Moreover, the three elements; I4.0, LMP, and LMSs are significant with 0.897, 0.980, and 0.876 values, respectively. The outcomes indicate a strongly positive correlation between I4.0 and LM system (LMS). This observation is expected to help Malaysian LM practitioners to anticipate the future lean landscape based on the boundless innovation provided by these Technologies as the anticipated outcome is a strong positive correlation between I4.0 and LM systems (LMS). This finding would empower Malaysian LM practitioners to anticipate the future of lean manufacturing, shaped by the boundless innovation potential of I4.0 technologies. By embracing this convergence, companies can unlock a future of enhanced productivity driven by autonomous operations and data-driven decision making. Therefore, using lean in the context of I4.0 is a promising combination for improving future productivity through autonomous operations.

Development of a Value Stream Map to Optimize the Production Process in a Luxury Metal Piece Manufacturing Company

The current market is highly competitive, and customers are increasingly demanding. In this context, organizations need to adopt tools that enhance process efficiency to ensure competitiveness. This report aims to implement Lean tools, specifically Value Stream Mapping (VSM) and complementary tools, to optimize the production process in the metal treatment industry. A case study was conducted, beginning with a brief sector and process recognition, followed by an analysis of production stages using VSM. Value-added activities, non-value-added activities, and waste were identified. The current VSM revealed a Lead Time (LT) of approximately 336 h (14 days), value-added activities (VA) of 21 h, and a process cycle efficiency (PCE) of 6.29%. Improvement actions were proposed to reduce waste and increase competitiveness. After implementation, the LT decreased to approximately 318 h (13 days), VA increased to 23 h, and process efficiency improved to 7.15%. Despite the limitations of VSM in discontinuous flows, its use increased process efficiency, demonstrating its applicability in complex industrial contexts.

A lean approach to enhance the visual experience during wayfinding in the emergency department spaces: a case study of a large-scale general hospital in China

ABSTRACT The wayfinding experience in the healthcare environment significantly impacts patients’ spatial cognition, mental health, and medical outcomes. However, patients often face challenges in wayfinding, encountering difficulties, and information gaps that result in negative emotions and decreased efficiency of medical services. This study proposes a Lean-led approach, coupled with eye-tracking simulation software analysis, to investigate the visual behavior of patients in the emergency department spaces and identify areas in medical environments that require improvement. The research methodology involves capturing images of 70 location nodes along the patient's route in ED spaces. Subsequently, the Lean tool, Value Stream Mapping, is employed to analyze the wayfinding process, dividing it into eight tasks and determining the visual information needs of patients during wayfinding. Moreover, the eye-tracking simulation software, 3M-VAS, is utilized to analyze the visual content of images and compare whether it meets the information needs of patients during wayfinding, thus identifying locations that require optimization. Finally, suggestions for optimization are proposed. The study identifies five types of visual environment problems during the wayfinding process and identifies 50 location nodes that need improvement, categorized into five types of visual environment issues. This paper explores how Lean theory can enhance the relevance of a patient-centered healthcare environment and introduces a methodology that connects hospital administrators and designers. However, this paper also has some limitations, such as the research scope, method, and angle, that need more exploration.

Synergizing FMEA and PDCA for superior risk management and process improvement in the semiconductor industry: a case study

The semiconductor industry faces the dual challenge of risk assessment and process improvement. This paper introduces a framework that integrates Failure Mode and Effects Analysis (FMEA) and Plan-Do-Check-Act (PDCA) cycle to address these challenges effectively. FMEA serves as the initial step to identify potential risks within the system, followed by applying the PDCA cycle to systematically address and enhance the identified risks. The comparison between the initial Risk Priority Number (RPN) value, determined through FMEA, and the post-RPN in PDCA value gauges the success of the framework. Implementing the system in a semiconductor assembly line yielded a significant 51% improvement in RPN, with additional Lean tools incorporated into PDCA, such as SMART goals, 6M, and multi-voting. This integrated framework amplifies risk management, fosters continuous improvement, optimizes resource utilization, and empowers data-driven decisions, ultimately bolstering organizational growth. However, the study acknowledges limitations such as its single-case focus and potential RPN calculation subjectivity.

THE ROLE OF LEAN ACCOUNTING METHODS IN COST REDUCTION: EXPLORATORY STUDY FOR A SAMPLE OF INDUSTRIAL INSTITUTIONS IN BLIDA STAT

Objective: The aim of this study is to examine the role of lean accounting methods in cost reduction, and how the lean accounting methods are implemented in the modern manufacturing environment Theoretical Framework: Identifying the different meanings pertaining to the lean accounting and defining the principles, practices and tools for lean accounting enforcement. Method: this study was an exploratory study of 180 employees in ten industrial institutions of Blida Stat, using the questioner tool and “Microsoft Excel” for unloading data and the Statistical Packages for Social Sciences SPSS V25 for processing data, analyzing and explaining results. Results and Discussion: This study concluded that lean accounting methods contribute in costs reduction from three aspects which are save costs in product planning and designing phase then avoid additional costs in product implementation phase, It also contributes to profit maximization, competition support, and maximizing the value of products from the customer's perspective. Research Implications: The findings suggest providing the elements for implementing the lean accounting tools through replacing the wide production system by the lean production one in order to reduce wastage Originality/Value: Our study is different from the previous ones as it is among the modern and few studies particularly in the Algerian environment. The study focuses indeed on bringing out the probable implementation of the lean accounting tools in the productive corporations and its contribution in reducing costs in the industrial corporations

Adopting Industry 4.0 technologies through lean tools: evidence from the European Manufacturing Survey

PurposeIn recent years, the emergence of Industry 4.0 technologies as a way of increasing productivity has attracted the attention of the manufacturing industry. This study aims to investigate the relationship between Industry 4.0 technologies and lean tools (LTs) by measuring how the internalisation of LTs influences the adoption of Industry 4.0 technologies and how the synergy between them helps improve productivity in European manufacturing firms.Design/methodology/approachResults from 1,298 responses were used to analyse linear regression and study the correlation between the use of LTs and Industry 4.0 technologies.FindingsResults show that the companies analysed tend to implement more Industry 4.0 technologies when their level of lean internalisation is high.Originality/valueThis study provides useful information for managers of manufacturing firms by showing the correlation between LT internalisation and Industry 4.0 technologies, corroborating that optimal implementation of these technologies is preceded by a high level of LT internalisation. Furthermore, although there are studies showing the relationship between LTs and Industry 4.0 technologies, none consider the intensity of their implementation.

Evaluation of Performance Enhancement in Garment Industry Using Lean Tools

The comprehensive idea of lean manufacturing emphasizes the identification and removal of wastes related to production. Increased productivity, shorter lead times, improved line balancing, lower work in progress (WIP), higher quality, more adaptable designs, lower costs, etc. are all major objectives of applying lean tools. This study aims to investigate how lean manufacturing techniques might enhance manufacturing efficiency in Bangladeshi RMG sector. The sewing section of a small scale garment industry was the focus of this study. In the study, the existing line layout of a trouser style was examined using value stream mapping which contributed to the identification of numerous waste in the existing layout. In order to change the current status of the sewing section, the workplace was organized by 5S tools to remove wastes identified by VSM followed by altering the conventional longer line layout into three cell of work station as suggested by cellular manufacturing. After implementation of these lean tools, results observed include, production output is increased by 17.80%, efficiency is increased by 12.46%, SMV of product is standardized to 18.68 min., defects per hundred units is reduced to 10% and order change over time is reduced by 37%. The conclusions reached during the execution of this implementation study are realistic and applicable in industries with similar structures. GUB JOURNAL OF SCIENCE AND ENGINEERING, Vol 10(1), 2023 P 27-36

Diagnostics of production processes using selected Lean Manufacturing tools

Diagnostics of production processes using selected Lean Manufacturing tools

Optimizing Production Line Efficiency through a Standardized Work Tool: A Case Study

Lean methodology focuses on enhancing flow and resource efficiency by prioritizing customer value, eliminating waste, reducing variation, and fostering a culture of continuous improvement involving everyone in the organization. Implementing lean creates conditions that empower all employees to contribute to continuous improvement activities within the value stream. This approach not only lowers production costs, enabling reinvestment and employee engagement but also emphasizes professional development. This paper aims to maximize efficiency in seal production within a manufacturing industry by implementing lean tools such as standardized work and Kaizen. Standardized Work is a systematic method for producing parts or services centred on human motion. As a tool for ensuring quality, it defines efficient, safe work methods and helps eliminate waste, serving as the foundation for every operation. Once implemented, standardized work ensures that the same methods are repeated consistently, avoiding unnecessary motions, maintaining quality, ensuring safety, and preventing equipment damage. The consistent application of these methods improves product quality through standardized processes and procedures. By incorporating lean tools like defined worksheets and Kaizen, the production of seals in manufacturing industries can achieve significant productivity enhancements.

Assessment and analysis of the effects of implementing building information modelling as a lean management tool in construction management

PurposeThe purpose of this research paper is to investigate and evaluate the impacts of utilising Building Information Modelling (BIM) as a lean management tool in Bangladesh's construction management field. The paper explores how adopting BIM as a lean management tool can improve and expedite a number of processes in building projects, which will ultimately increase project success, cost-effectiveness and efficiency.Design/methodology/approachA comprehensive survey was conducted to investigate how BIM deployment as a lean management tool affected project outcomes. This research involved a structured survey amongst construction professionals and a case study on a real project in Bangladesh to assess the effects of using BIM as a lean management tool. The data collected from 112 respondents were analysed statistically and qualitatively to identify the effect of BIM as a lean management tool. Additionally, several software tools, including Revit, Navisworks, Design Review and BIM 360, were used to compare conventional and BIM-based methods.FindingsThe research findings demonstrate that utilising BIM practices improves the quality and safety of construction in Bangladesh. The “Improving the quality of construction” (RII = 0.732) achieved the highest rank in the questionnaire survey. In addition, the case study represents that the construction industry can benefit from BIM-based project management. The BIM implementation can shorten the design process by over 50% and save up to 1.5 weeks by minimising idling time. By applying BIM, it is possible to avoid a price rise of roughly 2.5% and a delay of about 11.9% of the original contract period.Practical implicationsThe significance of the results goes beyond the direct advantages of the project's achievements. The successful integration of BIM as a lean management tool in Bangladesh's construction sector suggests transformative potential for the industry. The enhanced coordination and decreased errors point to a future where construction projects can achieve higher levels of precision and reliability. The improved efficiency observed implies a more sustainable and cost-effective future for construction projects in the region.Originality/valueThe research provides a unique perspective on the impact of BIM implementation on project outcomes. It includes a comprehensive survey on BIM adoption as a lean management tool, gathering real-world experiences from construction professionals in Bangladesh. The case study explores the practical implications and advantages of implementing BIM in construction projects. By comparing conventional methods with BIM-based approaches and utilising BIM software, the study contributes value to the construction sector.

THE APPLICATION OF LEAN MANAGEMENT METHOD IN OPTIMIZING ADMINISTRATIVE EFFICIENCY IN SCHOOLS

This study aims to explore the implementation of the Lean Management Method in optimizing administrative efficiency in Indonesian schools. The research method used is a qualitative approach involving data collection through in-depth interviews with relevant stakeholders in several schools. The research findings indicate that the application of Lean Management principles, such as identifying waste in administrative processes, using Lean tools and techniques such as Value Stream Mapping and 5S, and fostering a culture of Kaizen, has had a positive impact on improving productivity and the quality of educational services in these schools. However, challenges such as resistance to change and a lack of understanding of Lean concepts are also identified as obstacles that need to be addressed in implementing Lean Management in the education sector. The conclusion of this research emphasizes the importance of considering social and cultural aspects in the change process, as well as involving all members of the school community in improvement efforts. Recommendations for further research include exploring the long-term impact of Lean Management implementation on educational quality and stakeholders, as well as delving into more effective strategies to address challenges in implementing Lean Management in the Indonesian education environment.

Using the Lean Thinking Tool (5S) to reduce the costs of health services

Using the Lean Thinking Tool (5S) to reduce the costs of health services

Leveraging Lean Six Sigma principles in an Indian tertiary care hospital: a case study

PurposeWorkflow optimisation is crucial for establishing a viable acute stroke (AS) intervention programme in a large tertiary care centre. This study aims to utilise Lean Six Sigma (LSS) principles to enhance the hospital's workflow.Design/methodology/approachThe Action Research methodology was used to implement the project and develop the case study. The study took place in a large tertiary care academic hospital in India. The Define-Measure-Analyse-Improve-Control approach optimised the workflow within 6 months. Lean tools such as value stream mapping (VSM), waste audits and Gemba were utilised to identify issues involving various stakeholders in the workflow. Sigma-level calculations were used to compare baseline, improvement and sustainment status. Additionally, statistical techniques were effectively employed to draw meaningful inferences.FindingsLSS tools and techniques can be effectively utilised in large tertiary care hospitals to optimise workflow through a structured approach. Sigma ratings of the processes showed substantial improvement, resulting in a five-fold increase in clinical outcomes. Specifically, there was a 43% improvement in outcome for patients who underwent acute stroke revascularisation. However, certain sigma ratings deteriorated during the control and extended control (sustainment) phases. This indicates that ensuring the sustainability of quality control interventions in healthcare is challenging and requires continuous auditing.Research limitations/implicationsThe article presents a single case study deployed in a hospital in India. Thus, the generalisation of outcomes has a significant limitation. Also, the study encounters the challenge of not having a parallel control group, which is a common limitation in quality improvement studies in healthcare. Many studies in healthcare quality improvement, including this one, are limited by minimal data on long-term follow-up and the sustainability of achieved results.Originality/valueThis study pioneers the integration of LSS methodologies in a large Indian tertiary care hospital, specifically targeting AS intervention. It represents the first LSS case study applied in the stroke department of any hospital in India. Whilst most case studies discuss only the positive aspects, this article fills a critical gap by unearthing the challenges of applying LSS in a complex healthcare setting, offering insights into sustainable quality improvement and operational efficiency. This case study contributes to the theoretical understanding of LSS in healthcare. It showcases its real-world impact on patient outcomes and process optimisation.

Deployment of Lean Manufacturing in Palm Oil Mill for Maximum Yield: A Case Study of Leading Palm Oil Producer in Nigeria

The deployment of lean manufacturing in the palm oil mill companyaimed at maximizing yield, was thoroughly investigated. The company has been experiencing a decline in palm oil production, adversely affecting productivity and customer satisfaction. The methodology employed for optimization encompassed a comprehensive system description, detailing the case study company's history, operational modalities, production machinery, and system challenges. To gather a holistic understanding of the company's current situation, data was meticulously collected through questionnaires, examination of company records, and other relevant sources. Microsoft excel software was then utilized to analyze the acquired data. The implementation of lean manufacturing tools, such as the fishbone diagram, identification of eight deadly wastesand takt-timeplayed a pivotal role in streamlining operations. In addition, a quantitative model of the supply chain was applied, utilizing critical path method (network analysis) to determine the optimal route. The results derived from the application of lean manufacturing tools and the supply chain quantitative model exhibited a remarkable improvement between (2012-2016) and (2018-2022). The average oil palm extraction increased substantially from 8.67% (2012-2016) to an impressive 30.52% (2018-2022). Furthermore, the management tools led to a significant reduction in machine downtimes, decreasing from an annual average of 5,498.6 hours to 2,472.4 hours. This improvement resulted in a considerable reduction in the annual total average cost of machine maintenance, plummeting from #1,899,578.6 to #261,853.8. The optimization efforts also extended to the supply chain, where selecting Path-2, exhibiting the least total supply time of 11 hours, significantly reduced the cost of supply from an average of #2,168,402 to #1,893,186. Overall, the net revenue of the company witnessed a remarkable surge of 71.99% post-implementation of these management tools. This comprehensive approach not only addressed production challenges but also had a substantial positive impact on the company’s financial performance. The strategic deployment of lean manufacturing emerged as a catalyst for sustainable growth and enhanced operational efficiency.

Plumbing waste reduction through lean tools: A case for high-rise building construction

Plumbing waste reduction through lean tools: A case for high-rise building construction

Using a lean management approach in acute ischemic stroke management: a systematic review.

Stroke is the second leading cause of death worldwide with an annual mortality rate of 6.55 million, which accounts for 11.6% of the total number of deaths. Early diagnosis is crucial for improving treatment outcomes. Lean management is an approach originating in the car manufacturing process derived from the Toyota Production System, which healthcare providers have recently adapted. The objective is to examine the use of lean practices in managing AIS in hospital settings. A systematic literature search was performed using MEDLINE and SCOPUS databases, including publications from 1st January 2000 to 20th September 2022. A total of 13 studies fulfilled the predefined inclusion criteria. The recombinant tissue plasminogen activator (rtPA) was used in 11 studies, in 2 studies in combination with mechanical thrombectomy (MT). MT alone was used in the other 2 studies. The value stream mapping was used in all included studies to analyze workflow in acute ischemic stroke (AIS) treatment. Outcome measures include mostly door-to-needle (DTN) time for rtPA treatment and door-to-puncture (DTP) time for mechanical thrombectomy. DTN time was assessed in nine studies and reached statistically significant results in five. DTP was examined in three studies; in two, statistically significant decreases in DTP were observed. Lean management can be a useful method for achieving key performance indicators in AIS, consistent with current guidelines. The results of this systematic literature review show that value stream mapping may improve the process of AIS treatment by reducing in-hospital delays. The field of research that focuses on implementing lean management tools in healthcare is increasing, with more publications appearing in recent years.

Gamification Approach for Interactive Learning of Lean Manufacturing Activities

The gamification approach is popular method in education as it has been widely utilized in many fields. The project focuses on designing a game for interactive learning of lean manufacturing activities to create an alternative learning method that would gain interest and efficiency in learning. Integration of gamification approach and interactive learning method was used to illustrate a virtual lean manufacturing education and training by means of users’ interaction towards provided interactive learning materials and participation in playing the designed game. Input of the project which is learning materials was developed by analysing numerous articles regarding common lean manufacturing tools and practices. Interactive elements such as animation, sound effects, lecture voice, and videos were applied in each learning material to deliver an adequate understanding of each topic. Construction of the game platform is being developed using ActivePresenter software which includes simulation videos of the production line using FlexSim software to visualize a real production floor which provides a clearer picture of the production system for users. The game should include a basic assessment of lean manufacturing practices by considering its complexity and difficulty level for users with inadequate or does not have experience in the field. The outcome of the project is expected to successfully design a basic game platform for lean manufacturing education by means of interactive learning. Users will be able to learn lean manufacturing systems using the designed interactive learning materials included in the games and self-assess themselves as the game publishes the correct and best answer option in case they answer wrongly.

Propuesta para la mejora en la reposición de inventario en una empresa retail peruana mediante herramientas lean

This research work aims to improve inventory replenishment in a retail company as it is essential for any company to meet product demand. Therefore, by analyzing the percentage of canceled orders within the retail company and using an Ishikawa diagram, it was determined that the absence of distribution centers led to cost overruns in the logistics process. By employing this methodology, the improvement proposal was divided into three stages: logistics hubs information collection and diagnosis; design and validation of the improvement proposal; and evaluation of the improvement proposal viability, risks and implementation time. These stages indicate that the proposed solution would involve establishing a logistics hub to serve as a low-cost distribution warehouse. Furthermore, during this research, we used the 5S methodology, one of the most popular lean tools, applicable to every department and action. Based on the analysis of the cost flow and economic scenarios, it is concluded that implementing the hub is feasible. This would not only increase product availability and assortment but also result in savings on transportation costs from the distribution center in Lima to the hub located in Tarapoto, Peru.

Influence of BIM and Lean on mitigating delay factors in building projects

Building projects are affected by various phenomena that can affect their success and continuity and, in the worst cases, can lead to project abandonment. The delay has been identified as one of the phenomena with the most significant impact and recurrence; therefore, mitigation actions are required. BIM and Lean Construction are two approaches with great potential to mitigate delay-generating factors. However, more studies need to be conducted to analyze their influence on mitigating schedule delays. Considering this gap, this paper focuses on analyzing the influence of Lean Construction tools, and BIM uses that favor mitigating the main factors that generate variations in the construction schedules of residential buildings. The research method was divided into five main stages: (1) delay factors identification; (2) BIM uses identification; (3) Lean tools identification; (4) questionnaire design, validation, and application; and (5) influence quantitative analysis. A total of 20 delay factors, eight BIM uses, and eight Lean tools were selected. Next, a consultation was conducted with 50 building project managers and two residential building projects were analyzed. The findings show that implementing BIM and Lean tools greatly influences mitigating delay factors such as errors and deficiencies in design documents, inefficient project planning and scheduling, and poor communication and coordination with designers. BIM uses that have a strong influence on reducing delays include 4D construction planning and 4D construction analysis and optimization. In the Lean domain, the Last Planner System (LPS) and collaborative meetings have a high influence on mitigating delays. This study provides valuable insights for construction project managers to improve overall project efficiency by optimizing the implementation of BIM uses and Lean tools.