Lean System Research Articles

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

Enablers and barriers for adoption of lean system: a mix method approach

This study is based on exploring the lean manufacturing practices in Pakistan's textile industries. This study adopts the triangulation method for deciding barriers to lean's implementation in Pakistan's textile sector. We used descriptive analysis for the interpretation of the data for quantitative analysis. We conducted root causes analysis through expert interviews and also identified enablers of lean implementation in Pakistan's textile industry using qualitative and quantitative analysis. After the interview, we learned that poor leadership, insufficient preparation, unavailability of local experts, confusion, and poor communication are crucial barriers to lean implantation. We have also identified drivers of successful lean implementation in lean. 5S is the most used tool in the local textile organisation. This paper examines the current situation of lean implementation in Pakistan. This paper highlights the leading causes in poor implementation of lean that can be addressed through the study's solution. This study could be a source of inspiration for small and medium-sized enterprises to apply lean in their organisation.

An integrated sustainable lean approach for the SMEs in India: A multi-level conceptual frame work

Sustainability has become the prime focus in most of the manufacturing industries in and around the world due to high competitive demand, recent alleviation of change in global climate and government policies. Lean Manufacturing (LM), on the other hand have been globally accepted and it is now the heart of production in the industrial sectors. Researches depict that the lean philosophy in most of the SMEs are not properly carried out in a progressive and continuous manner and are getting declined in course of time. Also the limited number of researches done in the triple bottom line (TBL) of sustainability adds to the de-escalation of lean philosophy in the industries. In short, lean is not getting sustained. In order to make a sustainable lean system, a multi-level model, which identifies the enablers and inhibitors of sustainability, has been developed. The details of which is included in this paper. 39 enablers and 27 inhibitors have been identified from different literatures and expert interactions. Incorporating the enablers and inhibitors in the sustainability pillars (Environment, Economic & Social), and lean ideologies, multi-level sustainable- lean (Sus-Lean) enabler model and inhibitor model has been carved out in this paper. This will give an insight on how to make a sustainable lean approach in the SMEs of India. Also, the future research orientations in this regard are proposed based on the models.

DEVELOPMENT OF VIRTUAL LEARNING SYSTEM (VLS) BASED ON MOODLE AS A PLATFORM ONLINE LEARNING IN THE COVIC-19

The objectives of this research are to; 1) Produce a Virtual Learning System (VLS) Based on Moodle as a Covid-19 Online Learning Platform; 2) Testing the Feasibility of the Virtual Learning System (VLS) from the Appearance and Practicality Aspects. This type of research is Research and Development (R&D) with the Borg and Gall development model. The Borg and Gall model was modified inti six (6) steps, needs analysis, planning, development, Implementation, revision. The subject of the trial involved two media experts, one material experts and 30 student from SMKN 1 Sorong, West Papua were selected randomly. The instrumen used collect data is a product validation questionnaire. The data obtained in the form of qualitative data which are quantified, the tabulated and analyzed descriptively. The results showed that; 1) Research This development has produced a Moodle-based Virtual Learning System (VLS). Moodle-based Virtual Leaning System (VLS) application passed the quality and practicality test by media experts; 2). The results of the trial of the media expert's product on the display aspect obtained a value of 89.5% very feasible criteria, while the practicality aspect was 90.0% practical criteria. Meanwhile, from the aspect of Usabily Virtual Learning system (VLS) based on moodle, 90% of students complete the lesson independently, then 98% of students understand the lesson.

Application of Data Mining in the Evaluation of Enterprise Lean Management Effect

In order to improve the effect of enterprise lean management, this study proposes a lean data mining algorithm based on the characteristics of lean data in enterprise management. This study connects data mining and lean production to study the data of enterprise management operation, proposes an intelligent data processing model suitable for modern enterprise management, and constructs the model function module in combination with the enterprise operation management process. Moreover, this study constructs an evaluation system for the effect of enterprise lean management based on data mining. The system provides a human-computer interaction interface, and operators can use various functions and services provided by the system through a visual interface. Through experimental research, it can be known that the enterprise lean effect evaluation system based on data mining proposed in this study can play an important role in enterprise lean management.

COVID-19 and the Decline of the Social State in Nigeria’s Federal Democracy

Abstract The impact of the COVID-19 pandemic cuts across all spheres of human life, and it has exposed fundamental weaknesses in political values, governance systems, public health and social life in different parts of the world. In Africa, although with relatively less death rates than initially predicted, the pandemic has also exposed weaknesses in the continent’s political and public health systems. This article analyses how Nigeria’s public health sector has fared against the COVID-19 pandemic in the face of a declining social state and an ascending political state within a skewed federal democracy. This is useful for testing the relationship between effective public healthcare delivery and political systems in Africa. Distinguishing between the social and political states, the article argues that the social state in Nigeria has declined further in the face of the COVID-19 pandemic. Dialectically, as the social state declines, the political state ascends, and this is reflected in the considerations that drive the strained intergovernmental relations which characterise the federal and state governments’ responses to the coronavirus. Therefore, like all countries of the world irrespective of ideological leaning and political system, Nigeria needs a strong state with a social component in the long term to combat COVID-19. In the short term, measures aimed at changing the behavior of Nigerians will help arrest the growing tide of infections and death rates.

Productivity improvement using SWCT principle in continuous manufacturing Industry: A case study

Lean manufacturing can extensively implement in manufacturing organization in order to remove the wastes in the processing line. It produces quality of products with minimum costs. This paper works on implementation of Standard lean promoter of Lean Manufacturing system in a process line. This paper discusses on a pilot study which was done to implement SWCT concept is one of lean practice where operator work is separated from machines work. Standard work combination tables specify exactly how all work is performed in the system. In SWCT value chain entire manufacturing system mapped in terms material utilization of man and machine is reviewed and analyzed. This method makes the system have positive impact on organizational performance and drive the industry to get better financial results to meet the target of the global market.

Study on the Preparation of Magnetic Mn–Co–Fe Spinel and Its Mercury Removal Performance

In this study, the manganese-doped manganese–cobalt–iron spinel was prepared by the sol–gel self-combustion method, and its physical and chemical properties were analyzed by XRD (X-ray diffraction analysis), SEM (scanning electron microscope), and VSM (vibrating sample magnetometer). The mercury removal performance of simulated flue gas was tested on a fixed bed experimental device, and the effects of Mn doping amount, fuel addition amount, reaction temperature, and flue gas composition on its mercury removal capacity were studied. The results showed that the best synthesized product was when the doping amount of Mn was the molar ratio of 0.5, and the average mercury removal efficiency was 87.5% within 120 min. Among the fuel rich, stoichiometric ratio, and fuel lean systems, the stoichiometric ratio system is most conductive to product synthesis, and the mercury removal performance of the obtained product was the best. Moreover, the removal ability of Hg0 was enhanced with the increase in temperature in the test temperature range, and both physical and chemical adsorption play key roles in the spinel adsorption of Hg0 in the medium temperature range. The addition of O2 can promote the removal of Hg0 by adsorbent, but the continuous increase after the volume fraction reached 10% had little effect on the removal efficiency of Hg0. While SO2 inhibited the removal of mercury by adsorbent, the higher the volume fraction, the more obvious the inhibition. In addition, in an oxygen-free environment, the addition of a small amount of HCl can promote the removal of mercury by adsorbent, but the addition of more HCl does not have a better promotion effect. Compared with other reported adsorbents, the adsorbent has better mercury removal performance and magnetic properties, and has a strong recycling performance. The removal efficiency of mercury can always be maintained above 85% in five cycles.

Adaptation of the Lean 6S Methodology in an Industrial Environment under Sustainability and Industry 4.0 Criteria

Industry 4.0 paradigms have a positive influence on standard operating procedures, methodologies used in Lean Manufacturing techniques and management models with sustainability criteria. Interdependencies and correlations have been found between Lean systems and Industry 4.0. The Lean principles of avoiding waste and zero defects are related to the cloud and big data paradigms. In a current workplace, there has been an exponential increase in digital information and the need to generate direct commitments to environmental management. This situation forces us to innovate and improve the management methodologies and models used in the industrial environment. The Lean 6S methodology must adapt and respond to new demands. In this work, an update of the Lean 6S methodology is carried out to guarantee increased productivity in the workplace through the organization of industrial resources, both physical and digital. A revision of the implementation procedure is proposed, which includes activities that generate a direct commitment to sustainability and the organization of digital information, through a proposal for an organizational architecture of Industry 4.0 technologies.

Lean Supply Chain System in Indonesian Banking Industry

The goal of this research is to identify, inspect, and assess the existing system, performance, limitations encountered, and lean supply chain solutions that may be used in the banking industry’s account opening process. The qualitative exploratory analytical research approach was utilized, using a sample of state-owned banks such as Bank Mandiri, Bank Negara Indonesia (BNI), and Bank Rakyat Indonesia (BRI). The process of developing a lean supply chain strategy include identifying problems using SIPOC and VSM tools, analyzing problems using VALSAT tools, improving processes using FMEA tools, and controlling processes using SQC tools. The system of account opening that is now in use in the banking industry is partial, the performance of the banking industry’s account opening system is not ideal, some of the issues that have arisen as a result of the banking industry’s account opening system include, among other things, an increase in the number of employees and a lack of ergonomic in the design of the teller machine, and Process Activity Mapping may be used in the banking industry as a lean supply chain strategy

Levers of social services integration: performance management system and Lean-related management tools

IMPACT This article provides a novel perspective on the use of Lean-related management approaches in the context of social services integration. While the literature on Lean and performance management systems in public services is growing, little has been published about social services. As the demand for such services is likely to keep increasing, organizations will be under more and more pressure to deliver accessible services. This article shows how organizations providing social services can leverage management systems and their tools to favour integration and improved performance.

What Determines Supply Chain Risk in the Age of Globalization? Implications for Procurement and Logistics Risk Management

Supply chain is one of the most important parts for the company and supply chain management plays an increasingly important role in business development. Supply chain risk has become a major obstacle to supply chain management, and it makes a deep influence on company`s operation and development. The intricacies of the supply chain network structure, the external environment of uncertainty and supply chain managers excessive pursuit of lean, making the supply chain is vulnerability and the supply chain is increasingly vulnerable to various risks impact. Lean supply chain system which more and more companies used can provide the potential benefits, but with the pursuing the ability to respond faster and at lower cost, this system is becoming more and more fragile, and the impact of risks and uncertainties should be more sensitive. Globalization let supply chain have become more uncertainties. The company`s procurement and logistics part have covered different countries or area, which lead to the supply chain risk higher than before. This paper analyses the background and definition of supply chain risk in procurement and logistics. And collect and analyse the risk management method to assess, evaluate, identify, and manage supply chain risk.

FORMATION OF A LEAN PRODUCTION CULTURE IN ORGANIZATIONS AS A FACTOR OF INCREASING LABOR PRODUCTIVITY IN A REGION (ON THE EXAMPLE OF THE TCHAIKOVSKY BRANCH OF JSC "GAZPROM BYTOVYE SISTEMY")

The article examines the relevance of creating a lean production management system as an organization of activities focused on increasing the attractiveness of the technical, economic and aesthetic qualities of a product or service for the consumer, achieving stable development of the organization through continuous improvement of business processes through the involvement of personnel and the elimination of all types of losses. The authors describe in detail the stages of the creation of the DARINA Operating System in the Tchaikovsky branch of Gazprom Bytovye Sistemy JSC. The importance of the formation of a culture of lean production among all participants in business processes has been substantiated. Research into the prevalence and effectiveness of lean manufacturing in the Perm Territory in general and in the Chaikovsky District in particular shows the growing interest of business and government in the implementation of lean manufacturing technologies. This situation contributes to the development of the organization as a conductor of the ideas of lean production in the region. At present, shaping the methodology for using the principles of lean production and the principles of lean management of sustainable development, providing support to enterprises of the Perm Territory, the Chaikovsky branch of JSC Gazprom Bytovye Sistemy is successfully developing and expanding the boundaries of its potential capabilities, not only in the production of products that best meet the needs of consumers in relation to quality, design and price, but also a more multifaceted implementation of the principle of social responsibility as a prerequisite for the sustainable development of the company through participation in projects aimed at strengthening social support for the population.

Development of Virtual Learning System Based On Moodle as A Platoform Online Learning tn the Covid-19 Pandemic

The objectives of this research are to; 1) Produce a Virtual Learning System (VLS) Based on Moodle as a Covid-19 Online Learning Platform; 2) Testing the Feasibility of the Virtual Learning System (VLS) from the Appearance and Practicality Aspects. This type of research is Research and Development (R&D) with the Borg and Gall development model. The Borg and Gall model was modified inti six (6) steps, needs analysis, planning, development, Implementation, revision. The subject of the trial involved two media experts, one material experts and 30 student from SMKN 1 Sorong, West Papua were selected randomly. The instrumen used collect data is a product validation questionnaire. The data obtained in the form of qualitative data which are quantified, the tabulated and analyzed descriptively. The results showed that; 1) Research This development has produced a Moodle-based Virtual Learning System (VLS). Moodle-based Virtual Leaning System (VLS) application passed the quality and practicality test by media experts; 2). The results of the trial of the media expert's product on the display aspect obtained a value of 89.5% very feasible criteria, while the practicality aspect was 90.0% practical criteria. Meanwhile, from the aspect of Usabily Virtual Learning system (VLS) based on moodle, 90% of students complete the lesson independently, then 98% of students understand the lesson

Sustaining safety and delivery of oral chemotherapy utilizing lean methodology.

218 Background: An oral chemotherapy safety event in 2017 prompted analysis of related workflows utilizing lean quality improvement methodology. Three kaizen workshops utilizing lean methodology with primary objectives to 1) develop safety standards for oral chemotherapy as rigorous as those for intravenous chemotherapy; 2) improve efficiency; and 3) design workflows that enable data collection and process control were conducted. Since 2017, our goal has been to sustain developed workflows to ensure oral chemotherapy patients have the right oral chemotherapy agent, at the right dose, at the right time, with independent and efficient safety checks by all care providers. Methods: After multidisciplinary teams participated in three kaizen workshops to develop workflows, education plans were developed and results were incorporated into the lean management system. The lean production method of Training Within Industry (TWI) was used to train physician, nursing, and pharmacy teams to the workflows. Results were communicated to key stakeholders weekly to monitor progress on workflow creation, spread, and process metrics designed to signal defects in the workflow. When processes were deemed ‘out of control,’ clinical team members provided regular and targeted interventions. Safety data were collected and correlated to surrogate outcomes for long-term impact assessment. Results: Interventions resulted in the following outcomes: 62 consecutive weeks with 99% reduction in oral chemotherapy defects reaching pharmacy. 86 consecutive weeks with 51% error reduction processing oral chemotherapy though a single EMR workflow. 57 consecutive weeks with 62% error reduction processing oral chemotherapy though a single EMR workflow. No serious safety events have occurred since 2017. Conclusions: Comprehensive quality improvement in our oral chemotherapy process has resulted in sustained safety, efficiency, and a data collection to signal when process defects occur. Multidisciplinary teams utilizing established lean methodology were critical to success.

Integration of green and lean practices for sustainable business management

AbstractThe integrated implementation of lean and green systems can assist managers in achieving environmental and economic performance. The benefits of this integration include improved quality of the environment, superior interactions with channel partners and consumers, reduction in lead times and overall costs, and so forth. This research seeks to evaluate the solutions for integrated implementation of green and lean practices to overcome the barriers in the manufacturing industry. The barriers are categorized as managerial, technological, organizational and cultural, individual and quality barriers. In this study, a fuzzy AHP and fuzzy TOPSIS based framework has been proposed. From the analysis, it is found that application of quality control tools, reduction in lead‐time, use of right first time approach and use of new technology and product innovations are the most significant among the solution alternatives that the manufacturing firms should consider to overcome obstacles in implementation of green and lean systems. To the best of authors' knowledge, this is the first study to examine prominent solutions to overcome barriers with regard to integrated operation of green and lean performance. The ranking of the solutions will be useful for managers in the manufacturing firms to make best strategic decisions for reducing their waste and improving performance. Mangers can concentrate on the most prominent solutions and formulate the appropriate strategies accordingly.

Application of machine learning and rough set theory in lean maintenance decision support system development

Lean maintenance concept is crucial to increase the reliability and availability of maintenance equipment in the manufacturing companies. Due the elimination of losses in maintenance processes this concept reduce the number of unplanned downtime and unexpected failures, simultaneously influence a company’s operational and economic performance. Despite the widespread use of lean maintenance, there is no structured approach to support the choice of methods and tools used for the maintenance function improvement. Therefore, in this paper by using machine learning methods and rough set theory a new approach was proposed. This approach supports the decision makers in the selection of methods and tools for the effective implementation of Lean Maintenance.

Implementation of Lean Manufacturing System in a machining company in the city of Igarassu-PE

A filosofia de gestão Lean Manufacturing, também conhecida como “Toyota Production System”, apresenta ferramentas que visam agregar mais valor ao produto ou processo, obtendo maior lucratividade e menor custo possível. Este trabalho tem por objetivo realizar um estudo de caso através da implantação da Metodologia Lean Manufacturing em uma linha de produção de uma indústria metalmecânica em Igarassu-PE, a fim de aumentar a produtividade e reduzir os desperdícios, propondo melhorias por meio de ferramentas do sistema Lean. Para este artigo foi utilizada uma metodologia de caráter descritivo e exploratório tendo como meios de investigação a pesquisa bibliográfica e o estudo de caso com a apresentação de propostas de melhorias e resultados atingidos. Após a implantação do sistema Lean Manufacturing no setor estudado, os ganhos alcançados foram a redução de 23% da área utilizada, a redução de 58% no estoque intermediário e o aumento da produtividade em 57%, mostrando assim a importância e a aplicabilidade deste sistema para a indústria. Palavras-Chave: Lean Manufacturing; Produtividade; Melhoria contínua.

Sequential SWARA and fuzzy VIKOR methods in elimination of waste and creation of lean construction processes

The lean manufacturing approach is one of the process improvement and business development philosophies that can be applied in all sectors. In this context, lean construction enables the development of common applications by combining the production sector and the construction sector under the name of lean in order to improve and develop construction processes. This study was carried out in order to help the creation of a lean construction system by selecting the most appropriate lean techniques to determine and eliminate the waste in construction processes and to reduce costs by increasing the efficiency of the processes. Within the scope of the study, the wastes arising in the construction processes and the selection of lean production techniques that can eliminate these wastes were discussed as a multi-criteria decision making problem. In this problem wastes were determined as decision criteria and lean techniques were determined as solution alternatives. The problem structure consists of 8 main criteria that are about overproduction, waiting, transporting, inventory, operation, movement, production and work accidents, 24 sub-criteria, namely, construction waste and 5 alternative lean techniques such as 5S Technique, Just in time production, Kanban, Total productive maintenance and Visual Management. In the solution phase of the problem, the criteria weights and importance order of wastes in the processes were obtained by using SWARA method, lean construction techniques were evaluated by using Fuzzy VIKOR method under fuzzy environment. As a result of the evaluations, on one hand among the 24 criteria in the construction processes, faulty construction due to the lack of integration between design and production and improper processes due to the operational mistakes made by the employees were determined as the most important waste and on the other hand Kanban and Visual Management were determined as the most suitable alternative lean techniques for the construction processes. According to this result, Kanban that can convey the demands of all the elements in the lean system to the previous process with all the details in line with their needs and Visual Management that can visualize all the work done in the system as much as possible should be used in construction processes primarily.

Technical and economic analysis of retrofitting a post-combustion carbon capture system in a Thai coal-fired power plant

Mitigating CO2 emissions is an important clean energy research topic. Post-combustion carbon capture is a well established and vital carbon capture technology for existing fossil-fueled power plants. In this work, monoethanolamine (MEA) based carbon capturing unit was designed using AspenPlus V.10 software for a 300 MWe power unit of Mae Moh power plant in Thailand. Technical and economic analysis of retrofitting a lean aqueous MEA system was investigated. From the simulation study, it was revealed that the optimal lean CO2 feeding for the amine-based carbon separation plant was about 0.2 mol/mol using packed columns with Sulzer Mellapak 250Y product. The optimal liquid-to-gas ratio with a flue gas containing 15% CO2 was approximately 3.0. Furthermore, the optimal total costs of the plants were less than 55 $/ton of CO2 captured.