Lean Training Research Articles

Impact of Lean Strategy Utilization Training program on Quality of Environmental and occupational safety.

Impact of Lean Strategy Utilization Training program on Quality of Environmental and occupational safety.

Fuzzy TISM and DEMATEL approach to analyze Lean variables in Indian Healthcare Industry

During the last few decades, due to rising competition, healthcare organisations have been trying their best to perform more efficiently by providing the best quality services to the patients. Lean is one of these performance improvement strategies that focus on delivering perfect services to the patients. However, lean implementation usually faces issues like employee resistance, poor follow-ups, and financial constraints, etc. The present research has identified 15 critical variables that affect the lean theory in the healthcare industry based on the review of existing literature with the expert's opinion in the healthcare sector as well as academia also. Fuzzy TISM 'fuzzy total interpretive structural modelling and DEMATEL methodologies' have been used to estimate the relationships among these variables. Results of both the methodologies depict that successful implementation of lean theory in healthcare organisations depend upon 'financial capability and lean training'. These key variables possess high driving power low dependent power.

Personnel resistibility in lean manufacturing

One of the barriers of the lean manufacturing introduction in enterprises is staff resistibility to change. The article describes the impact of philosophy and the concept of lean manufacturing training on the level of staff readiness for change. The research object is an engineering enterprise. Using the ROC technique, the authors conduct observations before and after training. The analysis shows that the number of neutral and positively inclined personnel increased from 70% to 82% after the training. Global practice indicates that it is possible to state the absence of barriers to implementation when the threshold is 80% according to these indicators.

KNOWLEDGE TRANSFER IN LEAN MANAGEMENT: EXPERIENCE FROM MALAYSIAN SME

This study explores how SME develops knowledge transfer in Lean management, particularly lean tacit knowledge. Lean tacit knowledge is very significant in ensuring the success of lean management implementation, yet the SMEs often found difficulties due to limited capital and resources. A single case study of Malaysian SME in the automotive industry was selected for this purpose. Results show that lean training, problem solving using case study, factory visit, sharing of lean database and online learning are the common approaches used by the studied company in developing the lean tacit knowledge. Moreover, the accomplishment of this knowledge transfer in lean management necessitatesstrong commitment from the employees and the top management support. This study incorporates some practical implications forthe organizations that aim to implement lean management effectively.

SurgeCon: Priming a Community Emergency Department for Patient Flow Management.

IntroductionCanadian emergency departments (ED) are struggling to provide timely emergency care. Very few studies have assessed attempts to improve ED patient flow in the rural context. We assessed the impact of SurgeCon, an ED patient-management protocol, on total patient visits, patients who left without being seen (LWBS), length of stay for departed patients (LOSDep), and physician initial assessment time (PIA) in a rural community hospital ED.MethodsWe implemented a set of commonly used methods for increasing ED efficiency with an innovative approach over 45 months. Our intervention involved seven parts comprised of an external review, Lean training, fast track implementation, patient-centeredness approach, door-to-doctor approach, performance reporting, and an action-based surge capacity protocol. We measured key performance indicators including total patient visits (count), PIA (minutes), LWBS (percentage), and LOSDep (minutes) before and after the SurgeCon intervention. We also performed an interrupted time series (ITS) analysis.ResultsDuring the study period, 80,709 people visited the ED. PIA decreased from 104.3 (±9.9) minutes to 42.2 (±8.1) minutes, LOSDep decreased from 199.4 (±16.8) minutes to 134.4(±14.5) minutes, and LWBS decreased from 12.1% (±2.2) to 4.6% (±1.7) despite a 25.7% increase in patient volume between pre-intervention and post-intervention stages. The ITS analysis revealed a significant level change in PIA – 19.8 minutes (p<0.01), and LWBS – 3.8% (0.02), respectively. The change over time decreased by 2.7 minutes/month (p< 0.001), 3.0 minutes/month (p<0.001) and 0.4%/month (p<0.001) for PIA, LOSDep, and LWBS, after the intervention.ConclusionSurgeCon improved the key wait-time metrics in a rural ED in a country where average wait times continue to rise. The SurgeCon platform has the potential to improve ED efficiency in community hospitals with limited resources.

Comparing Total Hemoglobin Mass Between Selected NCAA Division I Athletes And Recreationally Active Students

Total hemoglobin mass (tHb) is linearly related to total body mass, however, whether this relationship is altered by lean tissue mass, training or sex remains controversial. PURPOSE: To investigate if lean mass is a more appropriate determinant of tHb compared to body mass across NCAA DI athletes and controls. We will also determine if this relationship is altered by sex and/or training status. METHODS: Nordic (6F & 6M) and alpine (5M) skiers, football players (7M) and recreationally active student controls (9F & 10M) from the University of Colorado Boulder participated. The optimized carbon monoxide rebreathing procedure was used to determine tHb. Body composition was determined via DXA. Since female athletes were not present in all groups, statistical analyses were performed for males across all groups and a separate comparison was made between female nordic skiers and control groups. RESULTS: The overall correlations of tHb with body mass or lean tissue mass were significant (R2 = 0.73 & R2 = 0.88), but the positive relationship was stronger when using lean mass (p<0.001). For males, body mass and lean tissue mass were greater in football with no significant differences between any other group. Football had a greater tHb compared to control and alpine (1168.7 ± 126.9 vs. 925.9 ± 123.0 & 936.8 ± 151.9 g), but was not different than nordic (1052.5 ± 166.7 g). Nordic tHb was greater than control, but not different from alpine. When tHb was normalized using body mass and lean mass, nordic (14.5 ± 1.5 & 16.5 ± 1.2 g/kg) was greater than football (10.4 ± 0.9 & 14.4 ± 1.5 g/kg), alpine (11.6 ± 1.1 & 14.2 ± 0.6 g/kg) and control (11.8 ± 0.6 & 14.6 ± 0.8 g/kg) groups while no differences between any other groups were found. For females, body mass, lean tissue mass and tHB (656.4 ± 72.9 vs. 566.1 ± 66.0 g) were not different between nordic and control. When tHb was normalized using body mass, nordic (11.3 ± 0.7 g/kg) was greater than control (9.5 ± 1.0 g/kg), but when tHB was normalized using lean mass there was no difference (14.5 ± 1.1 vs. 13.8 ± 1.4 g/kg). CONCLUSION: Lean tissue mass explains a greater amount of variability in tHB compared to total body mass. In males, to examine the effect of endurance training on tHb, it is more appropriate to normalize by lean mass. Additional research is needed when comparing the effects of endurance training between female groups.

Knowledge transfer in Lean management: Experience from Malaysian SME

This study explores how SME develops knowledge transfer in Lean management, particularly the lean tacit knowledge. Lean tacit knowledge is very significant in ensuring the success of lean management implementation, yet the SMEs often found difficulties due to limited capital and resources. A single case study of Malaysian SME in automotive industry was selected for this purpose. Results show that lean training, problem solving using case study, factory visit, sharing of lean database and online learning are the common approaches that used by the studied company in developing the lean tacit knowledge. Moreover, the accomplishment of this knowledge transfer in lean management necessitate strong commitment from the employees and the top management support. This study incorporates some practical implications to the organizations that aims to implement the lean management effectively.

Integration of IT Into a Lean Basic Training: Target Group-Specific Insights and Recommendations

Abstract Lean Management and high cost automation are often seen as contradictory. Several studies however have shown that Lean Management and IT can actually match and complement each other. If the overall topic is the evolution of Lean from a simple tool box approach to a Lean 4.0 stage, this paper discusses how IT can be integrated into a Lean Basic Training. The training takes place in a traditional Lean learning factory with a real product and a real value stream. Combining a qualitative and quantitative approach, Lean experts and participants of a Lean Basic Training were asked if they saw any benefit in the use of IT in the training. In addition, they were asked which elements of the Lean training should be supported by IT. By applying inferential statistics, influences of target groups on IT integration were discovered. Among others, integration is significantly influenced by the companies the participants come from, by their level of education, their Lean experience and their IT affinity. Combining these influences of the target groups with insights from literature and the opinion of Lean experts from local companies, selected aspects of IT integration are discussed. Finally, recommendations are given how IT can be integrated into a Lean Basic Training in a traditional Lean learning factory.

Simulator-assisted lean production training

ABSTRACTIn Lean Production training and education, simulators are often used. These can take the form of for instance desktop games, computer simulations, or full-scale simulators. Many training participants perceive models for experiential learning and for continuous improvement processes as complex and abstract. Based on experiences from training sessions in a full-scale simulator Karlstad Lean Factory®, a unified model for learning and improvement work is presented. This model stimulates training transfer and is perceived as intuitive. It also shows instructional scaffolding as a learning method. Suggestions for future work include investigating synergy with Smart Manufacturing and the use of Lean Production simulators for innovative product realisation.

Implementing Lean in Academic Primary Care.

Lean is emerging as a quality improvement (QI) strategy in health care, but there has been minimal adoption in primary care teaching practices. This study describes a strategy for implementing Lean in an academic family medicine center and provides a formative assessment of this approach. A case study of the University of North Carolina Family Medicine Center that used the Consolidated Framework for Implementation Research to guide a formative evaluation. The implementation strategy included partnering with Lean content experts and creating a leadership team; planning and completing QI events and Lean training modules; and evaluating and reporting activities related to QI and training. During the initial period of Lean implementation, there was (1) minimal to no change in the quality of care as determined by the Preventive Care Index (46-48); (2) a decrease patient appointment cycle time from 89 minutes to 65 minutes; (3) an increase in overall practice productivity from $8144 to $9160; (4) a decrease in patient satisfaction from 94% to 91%; and (5) an increase in monthly visit volume from 4112 to 5076. Lean had an uneven effect on QI in an academic primary care practice during the first year of implementation.

Assessing the implementation processes of a large-scale, multi-year quality improvement initiative: survey of health care providers

BackgroundBeginning in 2012, Lean was introduced to improve health care quality and promote patient-centredness throughout the province of Saskatchewan, Canada with the aim of producing coordinated, system-wide change. Significant investments have been made in training and implementation, although limited evaluation of the outcomes have been reported. In order to better understand the complex influences that make innovations such as Lean “workable” in practice, Normalization Process Theory guided this study. The objectives of the study were to: a) evaluate the implementation processes associated with Lean implementation in the Saskatchewan health care system from the perspectives of health care professionals; and b) identify demographic, training and role variables associated with normalization of Lean. MethodsLicensed health care professionals were invited through their professional associations to complete a cross-sectional, modified, online version of the NoMAD questionnaire in March, 2016. Analysis was based on 1032 completed surveys. Descriptive and univariate analyses were conducted. Multivariate multinomial regressions were used to quantify the associations between five NoMAD items representing the four Normalization Process Theory constructs (coherence, cognitive participation, collective action and reflexive monitoring).ResultsMore than 75% of respondents indicated that neither sufficient training nor resources (collective action) had been made available to them for the implementation of Lean. Compared to other providers, nurses were more likely to report that Lean increased their workload. Significant differences in responses were evident between: leaders vs. direct care providers; nurses vs. other health professionals; and providers who reported increased workload as a result of Lean vs. those who did not. There were no associations between responses to normalization construct proxy items and: completion of introductory Lean training; participation in Lean activities; age group; years of professional experience; or employment status (full-time or part-time). Lean leader training was positively associated with proxy items reflecting coherence, cognitive participation and reflexive monitoring.ConclusionsFrom the perspectives of the cross-section of health care professionals responding to this survey, major gaps remain in embedding Lean into healthcare. Strategies that address the challenges faced by nurses and direct care providers, in particular, are needed if intended goals are to be achieved.

Game-based Lean Production training of university students and industrial employees

Production simulation games are increasingly popular for training students and industrial employees in Lean Production principles. They range from paper- or desktop-based games to full scale simulators and proper manufacturing machinery. This paper reports on experiences from using both desktop games and a full scale simulator. Desktop games are suitable when training people who already have a fair understanding of lean principles. Shop floor workers usually have difficulties in seeing analogies between desktop games and their work environment. For both students and industrial workers, training effects and immersion tend to be higher when using full scale simulators.

Impact of Martial Arts (Judo, Karate, and Kung Fu) on Bone Mineral Density Gains in Adolescents of Both Genders: 9-Month Follow-Up.

To compare bone mineral density (BMD) gains in adolescents of both genders stratified according to different martial art styles in a 9-month follow-up study. The longitudinal study consisted of 29 adolescents of both genders and age between 11 and 17 years stratified into a control group (not engaged in any sport) and 50 fighters (kung fu/karate, n = 29; judo, n = 21). All 79 subjects underwent anthropometric measures (weight, height, leg length, and height set) and dual-energy X-ray absorptiometry (BMD, in g/cm2) at 2 moments, baseline and 9 months later. Maturity offset (age at peak height velocity), lean soft tissue, chronological age, and resistance training were treated as covariates. Male judoists presented higher gains in BMD-spine [0.098 g/cm2 (95% confidence interval, 0.068-0.128)] than control group [0.040 g/cm2 (95% confidence interval, 0.011-0.069)] (post hoc test with P = .030). There was no effect of martial art on BMD gains among girls. Independently of gender, in all multivariate models, lean soft tissue constituted the most relevant covariate. Judo practice in adolescents affected the bone accrual significantly after 9-month follow-up compared with controls, mainly in boys.

Lean Operations Management in the Telecommunications Industry of Ghana: Triggers, Practices and Benefits

The purpose of this study was lean operations management, what triggers it, its practices and benefits to an organisation. Data was collected through a structured questionnaire among the departments in Millicom Ghana Limited. The analysis used was descriptive statistics and relative importance index for ranking of indicators. The result indicates the use of lean tools and techniques being the most observed lean operation practice. It was identified that the need to satisfy customers and the need to make savings on operational and capital expense were some of the major triggers for lean operations management journey. It was evident that some of the benefits of lean operations were improvement in revenue, elimination of waste, and savings in operational (OPEX) and capital (CAPEX) expenses. The challenges identified were lack of management support for lean operations, lack of lean training and high employee turnover rate. The paper suggests undertaking of value stream mapping analysis on the entire organisation for the sustenance of lean operations.

A Mixed Method Approach to Investigate the Lack of Lean Manufacturing Implementation in Libya

Lean manufacturing systems have been established to remove or diminish manufacturing waste and thus increase operational performance in manufacturing practices. The concept of lean thinking originated from the Toyota production system that determined the value-added activities or steps from non-value added activities or steps; and removing waste so that all phases add value to the process. This study examines the quality management processes which are utilized by Libyan manufacturing companies, and offers a methodology to develop a lean manufacturing framework. The literature review identified very few studies relevant to the use of quality improvement techniques in Libya; and no previous studies related specifically to waste reduction and lean systems, and the barriers that prevent lean manufacturing from being implemented in Libyan manufacturing companies. There are several difficulties that are facing lean manufacturing implementation in Libya such as lack of top management support, poor awareness of the importance of the system from workers, absence of lean training programs, and inadequate infrastructure and economic support. This paper presents types of mixed methods designs and the benefits of using them and the research methodology to develop an understanding in order to determine the barriers behind the lack of lean manufacturing implementation in the Libyan manufacturing sector. Having an understanding of the difficulties that face the implementation of lean manufacturing systems, as a new and modern system and using this to develop a suitable framework will help to improve the manufacturing sector in Libya.

Karlstad lean factory: an instructional factory for game-based lean manufacturing training

Simulation for training lean manufacturing ranges from simple paper-based or LEGO®-based games to larger scale simulation environments, for instance push car assembly. Some models for game-based learning are discussed and a model for lean manufacturing training is adopted. Many types of simulation may be suitable for teaching some basic elements of Lean manufacturing to students, but they are often less suitable for training industry workers in applying Lean manufacturing in their work environment. The latter group is more used to intuitive learning than to formal instruction. Thus, it is important that a training environment for this group more realistically represents the work environment; otherwise training transfer will be limited. For this reason, a lean training environment that includes materials processing stations as well as assembly areas was created. The stations exhibit some realistic behaviour such as stochastic breakdowns. Based on a comparison between factory workers and university students, five hypotheses for testing in future work are proposed.

A study on mean, lean and green management with reference to manufacturing industry

Lean systems are very good tools to make a company prosper. To make manufacturing process more efficient, a company must understand what lean is. Lean is an industrial practice where manufacturing facilities focus on waste reduction to create more value for the customer. There are several different lean techniques which allow each organization to fit lean into its unique production process. Advantages of lean manufacturing are higher productivity, improved customer service, increased profit, lower lead times, increased employee morale and a safer work environment. This paper illustrates the applications of lean methodology in manufacturing. Specifically, the objective of this research paper is to analyze the application of lean principles to streamline and standardize the establishment and maintenance of costing and planning for all manufacturing processes. Descriptive research method is used for the study. The population consists of employees of manufacturing companies, Bangalore. The obvious benefits of green and lean are energy savings, productivity savings, and savings from improved utilization of materials. They can also lead to innovations that involve creation of new products out of waste materials. The lean green implementation results in a significant reduction in the average cycle time and cost, and helps to improve the quality and productivity. From the hypothesis test it was revealed that lean training and reduction of errors are related. They depend upon each other. Using Chi-square test it is proved that benefits obtained by lean tools and commitment to the implementation of lean are associated.

The Concept of Ecologically Oriented Progress and Natural Resource Preservation

The most important issue of scientific and technological progress is considering the environment challenges of industrial development. It means that the progress must be ecologically oriented and environmentally friendly. The most adequate concept for the approach to the issue of “man - society – nature” relations is the ontology of the noosphere - the idea of a common space for human beings and nature. It presents an ideal example of an optimistic attitude towards the coordination between accelerating the scientific and technological development and natural resource saving. However, to maintain the balance between human needs and environmental processes determined by this concept, it is essential to include the lean production training into technological development of society.

Lean Production Training for the Manufacturing Industry: Experiences from Karlstad Lean Factory

Both literature and manufacturing companies state that simulators for providing training in lean production to industrial employees must be similar to the work environment. This motivated the design of Karlstad Lean Factory, which is a training environment that realistically resembles an industrial environment. It is a full-scale training facility that incorporates a combination of materials processing and assembly. Parameters such as processing times, breakdown intervals and repair types can be set. Examples of basic and more advanced training scenarios are given. Experiences from training groups of industrial employees are described; inhomogeneity of these groups requires some specific attention.

Affective atmospheres of hope: management model training in public reforms

PurposeThe purpose of this paper is to argue that we need to take seriously what affective atmosphere means in public reform. Particular emphasis is put on understanding the mechanisms of hope (Brunsson, 2006) through affective atmosphere (Anderson, 2009) in regards to a management model training course.Design/methodology/approachEthnographically, the paper is placed in a Lean coach training course, led by two consultants, in the public care services in a municipality in Sweden. The participants were set to learn the language and techniques of the Lean management model during the course of three training days.FindingsUsing affective atmosphere as a theoretical window for how to understand how participants become enthusiastic about public reform, the author puts forward that the enthusiastic, affective atmosphere created in the training room demanded the ingredients of consultants and the mechanism of hope at play. The consultants’ fashioning of the course contributed to the affective atmosphere. But what also triggered the affective atmosphere in the room was the participants’ way of responding, which was much more accidental and founded in the Lean model itself, promising smooth flows and rational organization, and the participants’ ability to keep mechanisms of hope active.Originality/valueFotaki et al. (2017) point out that affect has only recently started to be integrated and explored in critical organization studies. Michels and Steyaert (2017) emphasise that affective atmosphere has rarely been used by organization theorists. This is an attempt to contribute to this literature by arguing for the fruitfulness of understanding the mechanisms of hope through affective atmosphere in regards to public management reform. The author also calls attention to the need for ethnographic fieldwork when examining affective atmospheres.