Lean System Research Articles

Lean Manufacturing Assessment: Dimensional Analysis with Hesitant Fuzzy Linguistic Term Sets

Lean Manufacturing has become, in recent years, one of the most important philosophies for improving production and organizational systems. The literature shows that Hesitant Fuzzy Linguistic Terms Sets (HFLTSs) are highly capable of manipulating the uncertainty that the judgments made by evaluators carry and that they are subject to their perception, especially when used in combination with multicriteria decision making (MCDM) for the measurement of indicators in this type of system, as well as their general performance. However, it is still of interest to researchers to develop techniques and instruments that facilitate the measurement of the results obtained after applying this philosophy in organizations. This article proposes a model for the evaluation of the Lean Manufacturing performance through the Analytic Hierarchy Process (AHP) and Dimensional Analysis (DA) using HFLTSs. The results obtained show that the proposed model is a solid tool for the evaluation of Lean Manufacturing systems from a different perspective and that it can be integrated into the issuance of evaluations in a better way by considering human subjectivity. At the same time, it offers a strategy to create priorities in the action plans that Lean system managers propose after evaluating. However, it is important to apply the proposed model to multiple organizations and analyze the results obtained to maximize its benefits.

Intelligent algorithms and methodologies for low‐carbon smart manufacturing: Review on past research, recent developments and future research directions

AbstractSignificant attention has been given to low‐carbon smart manufacturing (SM) as a strategy for promoting sustainability and carbon‐free emissions in the manufacturing industry. The implementation of intelligent algorithms and procedures enables the attainment and enhancement of low‐carbon clever manufacturing processes. These algorithms facilitate real‐time monitoring and predictive maintenance, ensuring efficient and sustainable operations and data‐driven decision‐making, increasing resource utilisation, waste reduction, and energy efficiency. The research examines the utilisation of algorithms in the context of low‐carbon smart manufacturing, encompassing machine learning, optimisation algorithms, and predictive analytics. A comprehensive literature evaluation spanning from 2011 to 2023 is conducted to assess the significance of low‐carbon approaches in the context of smart manufacturing. An integrated approach is used using content analysis, network data analysis, bibliometric analysis, and cluster analysis. Based on the published literature the leading contributors to low‐carbon manufacturing research are India, China, United States, United Kingdom, Singapore, and Italy. The results have shown five main themes—Low‐carbon smart manufacturing and applications of Algorithms; Industry 4.0 technologies for low‐carbon manufacturing; low carbon and green manufacturing; Low‐carbon Manufacturing, and Product design and control; Lean Systems and Smart Manufacturing. The purpose of this study is to provide policymakers and researchers with a guide for the academic development of low‐carbon manufacturing by evaluating research efforts in light of identified research deficits.

The Nitrous Oxide Project: assessment of advocacy and national directives to deliver mitigation of anaesthetic nitrous oxide.

The environmental emissions attributed to anaesthetic nitrous oxide across the NHS are comparable to the carbon dioxide released by 135,000 flights from Frankfurt to New York. Much of these emissions are attributable to cumbersome and inadequately managed piped systems, resulting in excessive loss and waste. Since 2020, multiple hospital sites have been engaging with the Nitrous Oxide Project, a quality improvement method supporting a 'lean systems' approach to the provision of nitrous oxide. This review considers the frameworks supporting medical gas management in UK healthcare systems, and the impact of professional advocacy and medical gas stewardship to drive anaesthetic nitrous oxide mitigation in the NHS. Nitrous oxide mitigation efforts by grassroots and professional advocacy networks are enhanced through national centralised emission monitoring, distribution of data, technical information and provision of quality analysis. Given the climate harms of nitrous oxide, concerted efforts should be made to rationalise its use, and resources should be committed to supporting this at local, regional and national levels.

Lean manufacturing and quality management: Ways to improve efficiency

The reasons for the growing interest in lean manufacturing and quality management systems in engineering production systems are considered. It is shown that these systems currently work without proper efficiency. The essence of lean manufacturing and quality management concepts is considered. The main errors in their understanding and application are analyzed. It is established that it is expedient to implement these systems on the basis of research of processes of the organization's activity. The hierarchy of organizational and technological systems is considered and the main tasks solved within the lean manufacturing and quality management systems are presented. The tools of lean manufacturing and quality management are offered, which it is expedient to use in providing highly efficient machine-building production. Suggestions for restructuring of engineering departments of machinebuilding enterprises are given.

EGantryMate: A Piezo-Motor-Driven Lean and Flexible Assistance System for MR-Guided Interventions at 1.5T

eGantryMate: A Piezo-Motor-Driven Lean and Flexible Assistance System for MR-Guided Interventions at 1.5T

Application of project management tools in construction phases to optimize the impact on quality, cost, and time: A case study

This work deals with the disturbed construction process, evaluated using the parameters cost, time, and quality. The aim is to transfer the actual situation of the disturbed construction process into a structured construction process. In this context, the possibility of data analysis and the associated creation of a resilient initial situation is demonstrated. One factor, time, is classified into a measurability with the possibilities of Gantt and Lean Construction Management. A representation of the monetary situation is the determination of additional costs. Here, the best case and worst case are presented and evaluated. The execution of the quality requires the comparison with the fictitious, planning quality defaults at project initiation and the now under consideration of the default costs and dates possible degree of fulfilment. The realization at the considered object has the following initial situation. Construction delay approx. 1 year, delta costs approx. 250 million euros, quality approaches were revised and partly reduced. This was the base for the creation of a schedule. The milestones from the Gantt schedule were incorporated into the system for the Lean Construction system. The monitoring between the milestones or intermediate goals was measured in the target-actual comparison.

Lean management approach in health sector: MCDM model proposal to prevention of waste

Lean manufacturing in the manufacturing sector corresponds to lean management in the service sector. When health services are considered, it is seen that the concepts that are important in the manufacturing sector have the same importance for health services. Because waste is the main problem of every sector. Lean management approach in the health sector enables improvements by developing solutions to many other problems of healthcare professionals, patients and hospitals, such as reducing transaction costs, ensuring patient safety, and reducing processing times. This study was carried out with the aim of establishing a lean health system by selecting the most appropriate lean management methodology in order to identify and prevent waste in health processes and to increase efficiency and service quality. In the study, the evaluation of lean methodologies that can be applied to prevent waste in health services is considered as a multi-criteria decision-making problem and a model has been proposed. In the proposed model, wastes were determined as research criteria and lean methodologies were determined as research alternatives. The solution phase of the problem was carried out in two stages with multi-criteria decision-making techniques. In the solution phase, the importance weights of 24 decision criteria were calculated with the SWARA method, while 5 alternatives were evaluated based on the decision criteria with the WASPAS method and the most suitable alternative was selected.

Трансформация оперативного управления эксплуатацией станков, станочных комплексов с помощью «Системы операционного менеджмента»

The article focuses on the potential integration of the SFM digital control system into production. To achieve a more accurate implementation of the dSFM system, the article identifies its strengths and weaknesses. It evaluates and outlines the factors contributing to the successful implementation of the dSFM system in production. The article also analyses the traditional Lean manufacturing system, the analogue SFM system and its digital version. The study scrutinised the manner in which workers interact with the «System of Operations Management» with the purpose of refining its assimilation into manufacturing processes and enhancing employee output.

Methodology for Implementing a Manufacturing Execution System in the Machinery and Equipment Industry

In today's volatile, uncertain, and complex business environments, manufacturing companies must not only adapt to market demands but also minimize the time between problem occurrence and resolution. The implementation of lean manufacturing systems has been crucial in this regard. However, traditional approaches have shown notable inefficiencies that can be effectively addressed through digitalization. By embracing digital solutions, manufacturing companies can ensure efficient continuous improvement, driving performance to higher levels. This study aims to find a digital solution for a specific company that faces daily challenges associated with low visibility into production. An investigation revealed that the Lean tools used by the company were outdated, directly affecting the generated information and consequently, decision-making. The integration of a Manufacturing Execution System into the factory's dynamics was the solution found. In this context, a step-by-step methodology is proposed to guide the implementation. As a result, a prototype of the system was designed. The validation of the system by end-users demonstrates the success of the proposed methodology.

Integration of modified FMEA approach with Industry 4.0 technologies to improve reliability of lean systems

Integration of modified FMEA approach with Industry 4.0 technologies to improve reliability of lean systems

A systematic review of lean implementation frameworks and roadmaps: lessons learned and the way forward

PurposeThe purpose of this study is to carry out a comprehensive systematic review of lean implementation frameworks and roadmaps developed over the past decade and report the key findings along with the limitations and the way forward.Design/methodology/approachA systematic review methodology proposed by Tranfield (2003), was followed to identify the relevant works on the research topic. Articles were searched using a set of inclusion criteria in various databases including Google Scholar, Web of Science and Science Direct over a period of 30 years.FindingsThe high failure rate of lean system implementation, reaching a range between 70 and 90% in almost all industries, is a matter of concern. This failure rate is still high even though numerous frameworks and roadmap models exist to streamline lean implementation. There is no standard framework or roadmap identified in the literature and many organisations are implementing lean in their unique ways. However, it would be desirable to develop a practical and systematic roadmap on lean-looking into the cultural and leadership dimensions rather than focusing on a set of tools. Moreover, most frameworks and roadmaps lack the sustenance aspects of lean implementation.Research limitations/implicationsThis research only identifies the fundamental gaps with the existing frameworks and roadmaps on lean implementation. The next phase of the research is to develop a roadmap and validate it with a number of organisations in different cultural contexts and leadership styles.Originality/valueThe authors argue that this is one of the most comprehensive systematic review on lean frameworks and roadmaps, ever produced in the literature to date.

Subcarrier modulation based phase-coded coherent lidar.

This paper presents a lean subcarrier modulation-based phase-coded coherent lidar system with a non-quadrature receiver and sampling ratio lower than the Nyquist sampling ratio. Specifically, by utilizing the drawbacks of low Doppler tolerance in encoding signals, phase information can be obtained after pulse compression, and the mirror frequency introduced by real sampling can be negligible. Validation experiments based on inverse synthetic aperture lidar are performed, with the corresponding imaging results having a resolution superior to 4cm, demonstrating our system's efficiency in phase acquisition that is free from frequency aliasing.

Implementation of the Lean Healthcare System in the Emergency Room of the Clinical Hospital of the Federal University of Uberlândia: A Case Study.

The objective of this study was to analyze the effectiveness of the implementation of the lean healthcare system at the emergency room of the Clinical Hospital of the Federal University of Uberlândia, based on a comparison of hospital indicators obtained over the three phases corresponding to the period of one year before the implementation (T1), the year during the implementation (T2) and one year after implementation (T3). The methodology applied through this study can be classified as a case study that is exploratory and descriptive and developed in stages. Based herein on the search for hospital indicators, as occurred in the implementation of a lean process at the Clinical Hospital Emergency Department, along with a description of the implemented lean system. During the collection period of data relevant to the National Emergency Department Overcrowding Score and Length of Stay Indicator, the motivation of the teams grew, but with a notable tension between municipal management and hospital management. It was found that, despite the fluctuations, the patient length of stay in the Emergency Room remained high. With the exception of the variable of female deaths before 24 h of hospitalization, all other variables showed percentage increases before and after the intervention. This study reported the difficulties encountered by HC-UFU in implementing the lean project in an emergency room, thus ensuring that other institutions that intend to implement this project do not make the same types of mistakes.

The Effect of Using Lean Construction and BIM System Together on Waste in the Construction Industry

İnşaat sektöründe her yapının kendine has özellikleri nedeniyle farklı üretim kaynakları kullanılmaktadır. Bu nedenle inşaat sektöründe çok fazla israf oluşmaktadır. Günümüzde israf türlerinin önlenmesi için Yalın inşaat ve BIM sistemi gibi yaklaşımlar kullanılmaktadır. Bu çalışmanın amacı Yalın inşaat ve BIM sisteminin birlikte kullanılması durumunun israf türlerine etkisinin irdelenmesidir. Literatüre göre belirlenen israf türleri Yalın ve BIM konusunda bilgi sahibi ve/veya deneyimli kişilere anket uygulanmıştır. Elde edilen veriler RII analizi kullanılarak bu sistemlerin israf türlerine etkisi belirlenmiştir. Buna göre Yalın inşaat ve BIM sistemi kullanılması durumunda şantiyelerde, tüm israf türlerinin RII değeri 0,80’den daha büyük bulunmuştur. Ancak en çok azalan israf türleri sırasıyla fazla stoklamadan kaynaklı, gereksiz taşıma/aktarma ve hatalı/kusurlu üretim israflarıdır. Bu çalışmanın inşaat yönetimine, Yalın inşaat ve BIM sistemi ile ilgili konularda çalışan özel sektör ve akademik camiaya israf değerlendirilmesi ve azaltılması hususunda bir temel oluşturacağı öngörülmektedir.

Developing a Skilled Workforce for Future Industry Demand: The Potential of Digital Twin-Based Teaching and Learning Practices in Engineering Education

Engineering education providers should foresee the potential of digital transformation of teaching and skill-developing activities so that graduating engineers can find themselves highly aligned with the demands and attributes needed by prospective industrial employers. The advancement of industrial revolutions towards hybridisation of the enabling technologies recognised by Industry 4.0, Society 5.0, and Industry 5.0 have transformed the components of the engineering higher education system remarkably. Future workforce requirements will demand an employee’s multidisciplinary skill mix and other professional qualities. Implementing human-centric decision-making based on insights from the Digital Twin (DT) systems, sustainability, and lean systems is necessary for further economic growth. Recent barriers identified by the Australian Council of Engineering Deans, the development of teaching capabilities, and affordable and digitally transformed learning facilities by education providers were all considered. This paper explores the role of Digital Twins (DTs) in enhancing engineering higher education by incorporating Industry 4.0 components and other industrial advances. By reviewing curricula, pedagogy, and the evolving skill requirements for engineering graduates, this study identifies key benefits of DTs, such as cost-effectiveness, resource management, and immersive learning experiences. This paper also outlines challenges in implementing DT-based labs, including IT infrastructure, data quality, privacy, and security issues. The findings indicate that engineering education should embrace DTs to foster multidisciplinary skills and human-centric decision-making to meet future workforce demands. Collaboration with industry is highlighted as a crucial factor in the successful transformation of teaching practices and in offering real-world experiences. The COVID-19 pandemic has expedited the adoption of DT technologies, demonstrating their utility in minimising educational disruptions. While this paper acknowledges the high potential of DTs to prepare engineering students for future industry demands, it also emphasises the need for professional development among educators to ensure effective and balanced implementation.

Identifying the significant causes of waste of housing infrastructure projects in the Kingdom of Saudi Arabia

Construction waste issues have worsened globally due to the fast development of construction activities. The environment, expenditures, duration, productivity, and social dimension of the country are all negatively impacted by construction waste. The construction sector needs an in-depth knowledge of the development and construction management waste to minimize its detrimental effects. The infrastructure works of housing projects play a substantial role in many economies, including Saudi Arabia. Lean is presented as an improvement management approach for construction projects through lean techniques (less waste, time, and cost). Thus, optimizing project profitability is considered. This paper introduces the adoption of Lean in the construction of Housing infrastructure works in Saudi Arabia, in which waste can be eliminated or reduced when the causes are identified, thereby improving the reliability, stability, and optimizing profitability of construction operations. This article aims to establish the main sources of waste in Saudi Arabia's housing infrastructure projects. A questionnaire survey was conducted among owners, consultants, and contractors in Saudi Arabia. The Partial Least Square Structure Equation Model (PLS-SEM) and Relative Importance Index (RII) methods were used to analyze the collected data. The main finding revealed that the ten most important causes of waste are distributed among owners, consultants, and contractors by 20%, 10%, and 50% using the PLS-SEM method. At the same time, those percentages differ in the case of using the RII method as follows: 20%, 80%, and 0%. The consultant's causes have a mutual influence on the owner's causes and the consultant's causes. The research is considered one of the first such studies in the Kingdom of Saudi Arabia (KSA) and may enhance stakeholders' understanding of performance improvement from a lean system viewpoint in the Saudi Arabian construction industry.

Lean Optimization of Batch Production in an Aluminium Company

This work investigates the optimization of a batch type of production and operational management in an aluminium company using a lean manufacturing system. The operation and production system of the case study company runs in various sectors, which led to waste in the system, hindering the company's ability to meet customer demand. Through operational data analysis and questionnaires, the team identified the types of waste generated by the case study company. Lean manufacturing techniques such as eight deadly wastes, Heijunka, takt time, 5S approach, quality tool management, value stream mapping, Kaizen, Kaban, Gemba, and top and bottom-level involvement were employed to manage the waste. The findings reveal defects in inventory, transportation, waiting times, and untapped ideas of employees, all of which significantly impact the company's performance. This allows for daily production of small batches of aluminium alloys (AA3001, AA3105, and AA3110) without issues, supported by the principle of pull production. Additionally, the application of Takt time results in a significant reduction of production time, leading to improved efficiency. The study also highlights the high interaction effect of transportation, defects, and inventory wastes on various production lines, such as the bogie fitting line paint line, and anti-intrusion. Among the lean manufacturing tools, Kaban, standard work, and 5S are identified as the most frequently used. The research findings provide valuable insights for manufacturing industry leaders to spot the performance gaps and enhance the application of lean manufacturing practices.

IOT: Key Automation Solution to Efficate the Lean System in Manufacturing Industry

The research paper is based on the secondary data of the published literature review. The paper is informative to the current and future techno-functional trends and transformations required in the industry for its growth. The research study is to make aware of the use of automation technologies like the Internet of Things (IoT) as an efficient and effective solution to lean implementation in the manufacturing and engineering industry. The research study is done to understand the strategic techniques and their applications of lean manufacturing systems. And add to it the use of technologies like Industrial IoT (IIoT), which will help the manufacturing industry to smoothly implement lean system. The study uses secondary data only and is kept for future research on quality and quantitative survey aspects to study the impact and effectiveness on financial performance and human resource productivity using automation for lean manufacturing systems.

Lean production, green supply chain management and environmental performance: a configurational perspective based on the Portuguese context

Purpose Organizations are faced with increasing pressure to engage in sustainable development. There is an ongoing discussion on how to incorporate green thinking into lean management systems. This study aims to investigate configurations of lean and green supply chain management (GSCM) practices associated with high environmental performance. Design/methodology/approach The study uses survey data from a sample of Portuguese manufacturing firms and apply fuzzy-set qualitative comparative analysis to examine the data. This configurational technique allows to capture the synergetic effect of lean and GSCM practices and identify distinct combinations leading to the outcome of interest. Findings Seven configurations of lean and green practices are associated with high environmental performance. The implementation of lean practices is required in all configurations. Analysis of alternative combinations reveals trade-offs between lean initiatives and environmental goals. Four configurations require low level of implementation of pull production. In one configuration, high environmental performance is achieved with low implementation of statistical process control and without lean employee involvement. Research limitations/implications This study expands the literature on lean management by identifying different strategies to integrate lean and GSCM practices to achieve high environmental performance. Practical implications The findings suggest different strategies to achieve high environmental performance. Managers need to selectively implement lean and green supply chain practices to achieve the desired combinatorial effect, which may require not to implement specific lean practices. Originality/value The study demonstrates the synergetic effects of lean and green practices on environmental performance using a configurational perspective. In addition, it identifies combinations that require a low level of implementation of specific lean practices.

Design UI/UX e-commerce photography services using the Lean User Experience Model and System Usability Scale (SUS) Assessment

Studio Citarasa Fotography (SCF) is a photographer business that has been operating for 5 years since 2017 with a total of 87 customers. This number of consumers according to interviews with the studio owners is very small because the studio has not stopped promoting both inside and outside the city. The objective of this research is to design the UI/UX e-commerce Photography Services website in the Citarasa Photography studio and implement the Lean UX Model based on simple and responsive design, understanding user wishes and needs, informative, interactive, complete, sustainable, and personalized. Research results based on the test scenario respondents/participants successfully completed all UI/UX tasks for e-commerce photography services without significant restrictions, but in the scenario there is little information provided about the possibility of making changes for iterations to become more responsive in which the screen can be adjusted to an android or tablet screen. In addition, the test results obtained using the System Usability Scale (SUS) were achieved with an average score of 89.25. It can be said that the score is in the best imaginable category with a scale of A. This means that based on usability, the data obtains a judgment that is acceptable or acceptable.