. The mission with the strategy is to obtain competitive production in Denmark and in Western Europe based on the right combination of manufacturing principles, motivated and trained employees, level of automation, and cooperation with suppliers and customers worldwide. The strategy has resulted in technical...
Muñoz Ellner, Sarah María
El Diccionario Bilingüe de Lean Manufacturing pretende ser un instrumento de apoyo a todo aquel que tenga la responsabilidad de planear, ejecutar o simplemente algún interés con las actividades de Lean Manufacturing, aportando así también conceptos claros tanto en castellano como en inglés, con el fin de entender de forma integral el alcance mismo que puede llegar a tener dicha filosofía, al igual que se proporcionara una serie de siglas y herramientas para la implementación del Lean Manufact...
Full Text Available This paper is an attempt to examine the implementation of Lean Manufacturing system in the Indian industries. Predominant elements of Lean Manufacturing, benefits gained after its implementation and obstacles observed by Indian Industry have been recognized. The results of this survey support the opinion that Lean Manufacturing had potential to improve the organizational performance of Indian industries. Nevertheless, Indian industries are required to be passionate to transform their manufacturing by adopting Lean manufacturing to gain the full benefits. A large numbers of literature papers are available on the better side of Lean manufacturing approach and its benefits gained by manufacturing organizations after implementation. But the adverse impacts of Lean manufacturing are not discussed to a great extent. Some drawbacks of Lean manufacturing are also highlighted in this paper.
Ichimura, Maki; Jahankhani, Hamid; Arunachalam, Subramaniam
Implementing lean manufacturing is a complex and everlasting task. The workers involving in production processes are the pivot of the lean manufacturing implementation. Training is known as a vehicle to assist the implementation process. Despite awareness of the training importance, so far, a little is available to assist to organise an efficient training. This paper summarises the overview of lean manufacturing and discuss the importance of human resource within lean implementation process. ...
Christensen, Irene; Rymaszewska, Anna
. Abstracting from the extant literature, the authors considered the competitiveness of manufacturing companies from two principal perspectives: the leanness of the ramp-up process and the new-value creation of quality managers. While much of the literature fails to acknowledge that the roots of lean actually......This article provides a theoretical overview of the concepts of lean and manufacturing ramp-up in an attempt to conceptualize the strategic areas in which lean philosophy and principles can be applied for continuous improvements. The application of lean principles during the final stage of a new...... product development process, that is, the ramp-up process, is a critical, early enabler of lean manufacturing. The manufacturing strategy literature conceptualizes a state of “leanness in operations,” which can consolidate both the concepts of lean and manufacturing ramp-up, providing a dual perspective...
Edwards, Kasper; Thye, Nina; Nielsen, Anders P.
Lean is currently the rationalization method of choice in the Danish manufacturing industry. This paper reports finding from three lean implementation cases. All cases are manufacturing companies focusing on upmarket products produced in small series. Prior to lean production was organized as sel...
Exploring Lean manufacturing in a holistic manner, this book helps organizations to implement Lean principles successfully by offering theoretical, empirical and practical knowledge. It empirically demonstrates how a successful Lean initiative can improve organizational efficiency, and incorporates valuable primary research to substantiate findings. It argues that Lean principles need to be applied throughout the value chain in order to be successful , and suggests that these tools need to be aligned with culture and change management. Chapters examine issues including Lean cultures, impediments to Lean, Lean and performance measurement, and the impact of Lean. Viewing Lean as a never-ending journey, this book provides a valuable resource to practising Lean managers, and specialist researchers and students, and also offers an important reference for organizations embarking on their Lean voyage.
Michelsen, Aage U
Begrebet Lean har gennem de senere år vundet en enorm udbredelse. Antallet af publikationer om Lean har været eksplosivt stigende, og mange virksomheder har gennemført eller gennemfører Lean-projekter. Er Lean et nyt koncept? Er Lean den eneste løsning? Kan Lean kombineres med tankegange og princ...... løsning af en anden produktionsopgave. I fjerde afsnit skitseres kort relationerne mellem Lean og to andre begreber, Six Sigma og TPM, der begge har samme mål som Lean, men forskellige udgangspunkter og forskellige indfaldsvinkler....
Jørgensen, Frances; Matthiesen, Rikke
The purpose of this paper is to investigate the ways in HRM practices are-and could potentially be-exploited to support lean manufacturing in practice. First, a review of the pertinent literature regarding HRM, SHRM, and lean manufacturing is presented to provide an understanding of the mechanisms...... by which HRM practices could, theoretically, be used to support a lean implementation. Data presented in the paper are derived from 1) a longitudinal case study on lean implementation and 2) from managers currently involved with lean manufacturing in a second company. The relevant literature and the data...... depicting the potential role in supporting HRM/lean integrated practices. The analysis of the model with respect to the theoretical background emphasizes a number of areas in which HRM could be more fully exploited in order to more successfully support lean implementation, for example, by stressing HRM...
Full Text Available Purpose: Lean Manufacturing System has emerged as an important area of research in Indian context. The requirement of Lean Manufacturing has increased due to defects in products (semi finished and finished and subsequent increase in cost. In this context, this study is an attempt to develop a structural model of the variables, important to implement Lean Manufacturing System in Indian automobile industry. Design/Methodology/Approach: Various variables of lean manufacturing system implementation have been identified from literature review and experts’ opinions. Contextual relationship among these identified variables has been set after carrying out brainstorming session. Further, classification of the variables has been carried out based upon the driving power and dependence. In addition to this, a structural model of variables to implement lean concept in Indian automobile industry has also been developed using Interpretive Structural Modeling (ISM technique. Questionnaire based survey has also been conducted to rank these variables. Findings: Eighteen variables have been identified from the literature and subsequent discussions with experts. Out of which, nine variables have been identified as dependent and nine variables have been identified as driver. No variable has been identified as linkage variable and autonomous variable. From the model developed, ‘Relative cost benefits’ has been identified as top level dependent variable and top management commitment as bottom level most independent variable. Research limitations/Implications: The model so developed is a hypothetical model based upon experts’ opinions. The conclusions so drawn may be further modified to apply in real situation. Practical implication: Clear understanding of interactions among these variables will help organizations to prioritize and manage these variables more effectively and efficiently to draw advantage from lean manufacturing system implementation
Full Text Available A small furniture production company has integrated lean tools and sustainability concepts with discrete event simulation modeling and analysis as well as mathematical optimization to make a positive impact on the environment, society and its own financial success. The principles of lean manufacturing that aid in the elimination of waste have helped the company meet ever increasing customer demands while preserving valuable resources for future generations. The implementation of lean and sustainable manufacturing was aided by the use of discrete event simulation and optimization to overcome deficits in lean’s traditional implementation strategies. Lean and green manufacturing can have a more significant, positive impact on multiple measures of operational performance when implemented concurrently rather than separately. These ideas are demonstrated by three applications.
Due the presence of lot of automotive Industry, Chennai is known as Detroit of India, that producing over 40 % of the Indian vehicle and components. Lean manufacturing concepts have been widely recognized as an important tool in improving the competitiveness of industries. This is a continuous process involving everyone, starting from management to the shop floor. Automotive Component Industries (ACIs) in Ambattur Industrial Estate, Chennai has formed special purpose vehicle (SPV) society namely Ambattur Industrial Estate Manufacturers Association (AIEMA) Technology Centre (ATC) lean manufacturing cluster (ATC-LMC) during July 2010 under lean manufacturing competitiveness scheme, that comes under National Manufacturing Competitiveness Programme of Government of India. The Tripartite Agreement is taken place between National Productivity Council, consultants and cluster (ATC-LMC). The objective is to conduct diagnostic study, study on training and application of various lean manufacturing techniques and auditing in ten ACIs. The methodology adopted is collection of primary data/details from ten ACIs. In the first phase, diagnostic study is done and the areas for improvement in each of the cluster member companies are identified. In the second phase, training programs and implementation is done on 5S and other areas. In the third phase auditing is done and found that the lean manufacturing techniques implementation in ATC-LMC is sustainable and successful in every cluster companies, which will not only enhance competitiveness but also decrease cost, time and increase productivity. The technical efficiency of LMC companies also increases significantly.
Ncube, Lisa B.
This article discusses the functions and effectiveness of games and simulations in the learning processes, in particular as an experiential learning methodology. The application of the game Lemonade Tycoon in the development of lean manufacturing concepts is described. This article addresses the use of the game to teach the principles of lean…
Irwan Sutirman Wahdiat
This research purpose to analyze the concept of Lean Manufacturing which is influenced by the role of JIT. This research uses a theoretical approach. This study portrait thinking companies that have yet to implement lean manufacturing and after doing the concept of lean manufacturing. This study shows that the concept of lean manufacturing can make the company more efficient and effective. This paper shows some lean manufacturing dimensions of the researchers previous researchers. This study ...
Ucenic Camelia Ioana
Full Text Available The implementation of lean manufacturing is one of the main tools for attaining a higher performance level in the Romanian organisations. The study uses data collected at middle management level from organisations located in Transylvania. The organisations come from different fields of activity and are in different stages of lean implementation. The article makes use of quantitative and qualitative instruments for the evaluation of lean in the above mentioned companies. Characteristics as waste reduction, cost, quality, product design have different approaches in the companies. Their way of approach gives useful information regarding the type of company from the point of view of lean manufacturing implementation. This knowledge provides a useful support at different managerial levels in the process of decision making.
Full Text Available Today, industries such as automotive and manufacturing industries deal with a lot of environmental regulations. Lean is a production strategy whose fundamental principles drive the industry towards a more effective production of goods and services. The eco-efficiency concept is primary to sustainable development and intends to provide more value with less environmental impact. The aim of this study is to identify and explore the contributions of Lean to reduce environmental impacts that naturally result from industrial activity.
Full Text Available The theory of lean manufacturing provides the quality of the products in minimum cost and pro-vides customer satisfaction. Today, the competition level is very high and every industry tries to supply high quality products in nominal cost, so lean is the latest tool to achieve. The objective of this paper is to study different lean concepts under various lean strategies. This study helps to find out the status of lean manufacturing and its ways of implementation. Also in this paper, there is a discussion about lean manufacturing concept, lean waste, lean strategies, lean barriers and cycle of lean implementation. This paper presents a literature review to clear the status of lean manufacturing and their strategies with help of collection of relevant papers.
Bellisario, Andrea; Pavlov, Andrey
This paper provides the first systematic look into the existing research on performance management (PM) practices employed in lean manufacturing organisations (LMOs). It adopts a systematic review method to examine the evidence generated in the period 2004 – 2015 and uses a comprehensive PM
Kristensen, Thomas Borup; Nielsen, Henrik; Grasso, Lawrency
with management accounting practices. Specifically, we document that Lean manufacturing is positively associated with Value Stream Costing, Lean visual controls and, more importantly, measures of labor and materials efficiency. Lean manufacturing is positively related to Lean thinking and both are positively...... associated with operational performance and so are Lean visual controls. We also document that the management accounting practices intervene affecting operational performance and they intervene with Lean thinking as well. Lastly, the relationship between Lean manufacturing and measures of labor and materials......Lean manufacturing has been adopted by numerous western companies as an answer to an increasing competitive environment. Lean manufacturing is seen as an enterprise-wide strategy encompassing a transformation of manufacturing practices, affecting companies’ management accounting practices and...
Diego Fernando Manotas Duque
Full Text Available Medición en Lean Manufacturing: Relaciones entre Actividades Lean y Métricas Lean Lean Manufacturing fue desarrollada por Toyota para satisfacer sus necesidades específicas en un mercado restringido y en tiempos de estrechez económica. Estos conceptos han sido estudiados y se ha comprobado su aplicabilidad en una amplia variedad de industrias. El objetivo de este artículo es el de integrar un conjunto de métricas que han sido propuestas por diferentes autores, de tal manera que sean consistentes con las etapas y elementos de implementaciones de Lean Manufacturing. Para lograrlo se presentan dos marcos de referencia para implementaciones Lean y los principales factores de éxito se utilizan como base para proponer métricas que identifiquen el avance en estos factores. Posteriormente se propone una tabla que cruza el impacto de las Actividades Lean sobre las métricas, postulando que muchos de los supuestos a priori sobre estos impactos deberían ser precisos. Finalmente se proponen algunas ideas para proyectos de investigación hacia el futuro y posibles extensiones de las aplicaciones propuestas aquí.
Manotas Duque Diego Fernando
Full Text Available Lean Manufacturing was developed by Toyota Motor company to address their specific needs in a restricted market in times of economic trouble. These concepts have been studied and proven to be transferrable and applicable to a wide variety of industries. This paper aims to integrate a set of metrics that have been proposed by different authors in such a way that they are consistent with the different stages and elements of Lean Manufacturing implementations. To achieve this, two frameworks for Lean implementations are presented and then the main factors for success are used as the basis to propose metrics that measure the advance in these factors. A tabular display of the impact of “Lean activities” on the metrics is presented, proposing that many a priori assumptions about the benefits on many different levels of improvement should be accurate. Finally, some ideas for future research and extension of the applications proposed on this paper are presented as closing points.
Full Text Available This paper examines the possibilities of a lean approach to non-manufacturing functions, i.e. a market-oriented organization. This refers to purchasing, shipment, storage, sale and delivery of goods; marketing, etc. A lean approach to business operations is discussed and several lean business methods are developed on the basis of which lean management can be used not only in manufacturing, but also in non-manufacturing organizations.
In this article a longitudinal study performed at a medium-sized producer of electronics is reported during which we studied the company’s manufacturing change process. Based on theories of outsourcing, reengineering and explorative case research a series of findings is identified which demonstra......In this article a longitudinal study performed at a medium-sized producer of electronics is reported during which we studied the company’s manufacturing change process. Based on theories of outsourcing, reengineering and explorative case research a series of findings is identified which...... degree of complexity by introducing many new product lines, without phasing out very many of the old products could be changed into a far less complex organisation through reengineering and outsourcing. This again opened up for the application of the tool kit in Lean Manufacturing, and through...
Shannon, Patrick W.; Krumwiede, Kip R.; Street, Jeffrey N.
Lean manufacturing, an outgrowth of the Toyota Production System, has spread far beyond the automobile industry and is seen by many leaders as a key management philosophy in the battle to compete on an international scale. Successful implementation of lean requires that managers and employees be educated in the proper application of lean tools and…
Engelund, Eva Høy; Friis, Alan; Breum, Gitte
This paper discusses how the production principles of Lean Manufacturing (Lean) can be applied in a large-scale meal production. Lean principles are briefly presented, followed by a field study of how a kitchen at a Danish hospital has implemented Lean in the daily production. In the kitchen...... not be negatively affected by the rationalisation of production procedures. The field study shows that Lean principles can be applied in meal production and can result in increased production efficiency and systematic improvement of product quality without negative effects on the working environment. The results...... show that Lean can be applied and used to manage the production of meals in the kitchen....
Ahmad Ahmad Nur Aizat
Full Text Available Lean manufacturing is a systematic approch could increase manufacturing competitiveness by identifying and elminating waste through lean tools. However, these tools are often categorized into different groups, continues to be difficult for companies to select the most appropriate lean tool to be adopted, especially in respect of the SMEs whose knowledge of lean tools and associated principles are limited. This study is to propose solution on how to implement appropriate lean tools in food manufacturing industry located at Rengit, Johor. Qualitative method is used as a methodology to see the changes after the implementation of lean tools. Interview session also a part of method to collect data from respondents. The finding from this paper shows that implementation of an appropriate lean tool will help to eliminate waste in industry sector, maintain and control the inventory, improve quality of the product and improve overall operational process.
Full Text Available Purpose: Lean Manufacturing is widely regarded as a potential methodology to improve productivity and decrease costs in manufacturing organisations. The success of lean manufacturing demands consistent and conscious efforts from the organisation, and has to overcome several hindrances. Industry 4.0 makes a factory smart by applying advanced information and communication systems and future-oriented technologies. This paper analyses the incompletely perceived link between Industry 4.0 and lean manufacturing, and investigates whether Industry 4.0 is capable of implementing lean. Executing Industry 4.0 is a cost-intensive operation, and is met with reluctance from several manufacturers. This research also provides an important insight into manufacturers’ dilemma as to whether they can commit into Industry 4.0, considering the investment required and unperceived benefits. Design/methodology/approach: Lean manufacturing is first defined and different dimensions of lean are presented. Then Industry 4.0 is defined followed by representing its current status in Germany. The barriers for implementation of lean are analysed from the perspective of integration of resources. Literatures associated with Industry 4.0 are studied and suitable solution principles are identified to solve the abovementioned barriers of implementing lean. Findings: It is identified that researches and publications in the field of Industry 4.0 held answers to overcome the barriers of implementation of lean manufacturing. These potential solution principles prove the hypothesis that Industry 4.0 is indeed capable of implementing lean. It uncovers the fact that committing into Industry 4.0 makes a factory lean besides being smart. Originality/value: Individual researches have been done in various technologies allied with Industry 4.0, but the potential to execute lean manufacturing was not completely perceived. This paper bridges the gap between these two realms, and identifies
Dan Cumbo; D. Earl Kline; Matthew S. Bumgardner
Lean manufacturing represents a set of tools and a stepwise strategy for achieving smooth, predictable product flow, maximum product flexibility, and minimum system waste. While lean manufacturing principles have been successfully applied to some components of the secondary wood products value stream (e.g., moulding, turning, assembly, and finishing), the rough mill is...
Ali Görener; Humeyra Baser; Ali Turkyilmaz
Lean production is a production model which comes about the pursuit of companies to be able to meet competition and make effective production. The main purpose of lean production is to get control about the wastage. This study includes the requirements for the success of the lean production and how the lean production system can be established. In this paper, lean production techniques were applied to the electric water heater line. Measurements using lean initiatives were made, operation cyc...
Full Text Available Abstract: Lean Manufacturing Implementation: An Approach To Reduce Production Cost. Opportunities to improve production processes and reduce production cost through the implementation of lean manufacturing in small medium garment manufacturing are presented in this research. This research shows that there is a possibility of decrease in production cost and increase in return on sales. Lean manufacturing implementation can eliminate waste in the production process. This is a set of techniques for identification and elimination of waste gathered from The Ford Production, Statistical Process Control and other techniques. Improvement of quality could be carried out while time and cost of production are being reduced.
Kumar Ahir, Pankaj; Kumar Yadav, Lalit; Singh Chandrawat, Saurabh
Productivity is the impact of peoples working together. Machines are merely an extended way of collective imagination and energy. Lean Manufacturing is the most used method for continues improvement of business. Organization management philosophy focusing on the reduction of wastage to improve overall customer value. "Lean" operating principles began in manufacturing environments and are known by a variety of synonyms; Lean Manufacturing, Lean Production, Toyota Production System, etc. It is commonly believed that Lean started in Japan "The notable activities in keeping the price of Ford products low is the steady restriction of the production cycle. The longer an article is in the process of manufacture and the more it is moved about, the greater is its ultimate cost." "A systematic approach to identifying and eliminating waste through continuous improvement, flowing the product at the pull of the customer in pursuit of perfection."
Full Text Available Lean production is a production model which comes about the pursuit of companies to be able to meet competition and make effective production. The main purpose of lean production is to get control about the wastage. This study includes the requirements for the success of the lean production and how the lean production system can be established. In this paper, lean production techniques were applied to the electric water heater line. Measurements using lean initiatives were made, operation cycle times were determined, and Kaizen improvement methods and line balancing methods were applied according to the results. And the last section of study showed conclusion of lean implementation.
Full Text Available The purpose is to compare similarities and divergences in how the concepts of Lean and barriers to Lean are described by key informants at a production unit in a large manufacturing company and two emergency health care units in Sweden. Data was collected via semi-structured interviews and analyzed with the constant comparative method (CCM and Porras and Robertson’s (1992 change model. : In both organizations, the view of Lean changed from a toolbox to a human behavior view. Eight barriers were experienced in both organizations. Three barriers were unique to manufacturing or to health care, respectively. Nine barriers were elements of social factors; five were elements of organizing arrangements. Only people practically involved and responsible for the implementation at the two organizations participated in the study. Persons responsible for implementing Lean should consider organizational arrangements and social factors in order to limit barriers to successful implementation. Most research on Lean has been about successful Lean implementations. This study focuses on how Lean is viewed and what barriers personnel in manufacturing and health care have experienced. In comparing the barriers to Lean experienced in the two groups, common, archetypical, and unique barriers for manufacturing and health care can be identified, thus contributing to knowledge about barriers to Lean implementation.
Christiansen, Thomas Bøhm
manufacturing companies in 2001-02. This study fills a void in existing research by exploring relationships between bundles of lean manufacturing practices and bundles of mass customization practices. This study is based on a questionnaire that is developed from two existing questionnaires each investigating...... bundles of lean manufacturing practices and bundles of mass customization practices separately. Here, these bundles of practices are related. The results indicate that there are no direct relationships between the lean manufacturing and the mass customization practices, but that the combination of some...... sets of practices can explain differences in performance on important dimensions. The general conclusion, however, is that there are only weak relationships between the two concepts, hence this study suggests that the concepts of lean manufacturing and mass customization at present are more mutually...
Alisson Christian Scheller
Full Text Available The connection among Lean Production with Six Sigma originated the Lean Six Sigma methodology, focused on processes variation and waste reduction. This methodology was developed on different ways in the companies and there is no consensus over its structure and its implementation. In this context, this paper aims to identify and analyze the main characteristics on the adoption and integration of Lean Six Sigma methodology through a case study conducted in a manufacturing company that adopts lean production and six sigma. The results show two important aspects of the Lean Six Sigma methodology. One of them is the adoption of the value stream mapping as a central tool on Lean Six Sigma. The other is the use of DMAIC for improvements actions. The study indicates that despite the difficulties on Lean Six Sigma implementation, the methodology offers benefits to the company that adopts it in the suitable way.
Sanders, Adam; Elangeswaran, Chola; Wulfsberg, Jens
Purpose: Lean Manufacturing is widely regarded as a potential methodology to improve productivity and decrease costs in manufacturing organisations. The success of lean manufacturing demands consistent and conscious efforts from the organisation, and has to overcome several hindrances. Industry 4.0 makes a factory smart by applying advanced information and communication systems and future-oriented technologies. This paper analyses the incompletely perceived link between Industr...
Full Text Available PT. XYZ is one of some cigarette companies in Indonesia. In producing cigarette, the firm requires a material named “etiket” which is produced by printing division for internal consumers of PT. XYZ. In order to produce “etiket”, there are some wastes occurred. One of wastes occurred in printing division is product defects. This paper attempts to identify wastes in the division of printing using Lean Manufacturing approach by applying Value Stream Mapping (VSM method. The results from cause root analysis found that the problems caused the defects in production process. It shows that the most wastes occurs in the printing division are product defect and waiting time. The product defects are caused because there is no standard applied in processing the product and poor inspections by management, while the causes of waiting time wastes is because of lack of carrier and no standard in each process. The recommendation can be suggested to the company are adding some carrier (product’s transporter, creating process standard in each process.
Full Text Available PT. XYZ is one of some cigarette companies in Indonesia. In producing cigarette, the firm requires a material named “etiket” which is produced by printing division for internal consumers of PT. XYZ. merupakan salah satu dari beberapa produsen rokok di Indonesia yang telah dikenal masyarakat. In order to produce “etiket”, there are some wastes occurred. One of wastes occurred in printing division is product defects. This paper attempts to identify wastes in the division of printing using Lean Manufacturing approach by applying Value Stream Mapping (VSM method. The results from Cause Root analysis found that the problems caused the defects in production process. It shows that the most wastes occurs in the printing division are product defect and waiting time. The product defects are caused because there is no standard applied in processing the product and poor inspections by management, while the causes of waiting time wastes is because of lack of carrier and no standard in each process. The recommendation can be suggested to the company are adding some carrier (product’s transporter, creating process standard in each process.
Ching, Ng Tan; Hoe, Clarence Chan Kok; Hong, Tang Sai; Ghobakhloo, Morteza; Pin, Chen Kah
The case study of lean manufacturing aims to study the application of lean manufacturing in a die casting manufacturing company located in Pulau Penang, Malaysia. This case study describes mainly about the important concepts and applications of lean manufacturing which could gradually help the company in increasing the profit by studying and analyzing their current manufacturing process and company culture. Many approaches of lean manufacturing are studied in this project which includes: 5S housekeeping, Kaizen, and Takt Time. Besides, the lean tools mentioned, quality tool such as the House of Quality is being used as an analysis tool to continuously improve the product quality. In short, the existing lean culture in the company is studied and analyzed, with recommendations written at the end of this paper.
Michelsen, Aage U.
Filosofi, principper og teknikker i JIT. Princip i Kanban-styring og dimensionering af et Kanban-system. Lean Thinking og Value Stream Mapping.......Filosofi, principper og teknikker i JIT. Princip i Kanban-styring og dimensionering af et Kanban-system. Lean Thinking og Value Stream Mapping....
Riezebos, J.; Klingenberg, W.
This introduction to the special issue discusses the changing role of information technology (IT) in advancing lean production. Lean principles and techniques have been applied in a wide variety of organisations, from make-to-stock to engineer-to-order industries, and even in typical service
Fansuri, A. F. H.; Rose, A. N. M.; Nik Mohamed, N. M. Z.; Ahmad, H.
Literature studies shows that lean manufacturing goes way back with the original founder Eli Whitney in year 1799. The main purpose of lean manufacturing is to identify and eliminate waste in production. The application of lean manufacturing can be carried out in any industrial processes with regards to the understanding of lean principles, theories and practices. Kitting is one of the important aspects in a successful production. The continuous supply of materials from store to production has to be systematic and able to achieve lean standard for it to be successful. The objective of this paper is to review the implementation of lean manufacturing in kitting assembly. Previous papers show that, the implementation of lean manufacturing in kitting assembly may be beneficial to the organization such as reduce in space occupancy, part shortages, lead time and manpower. Based on previous research, some industries may tend to change between kitting and line stocking which are due to lack of understanding when implementing kitting and causes longer lead time and materials overflow in store. With a proper understanding on what to kit, where to kit, how to kit, why to kit and who kits the material with a standardised process flow may ensure the success of kitting.
Ichimura, Maki; Arunachalam, Subramaniam; Jahankhani, Hamid
Lean Manufacturing (LM) has been one of the centrepieces of manufacturing enterprises since Toyota has magnificently improved its manufacturing performance through implementing Toyota Production System (TPS). Moreover, it has been proven that LM is the manufacturing system that improves shop floor performances. Success stories of LM have led a large number of manufacturing companies to attempt to implement LM in order to improve their shop floor performance and retain competitiveness. However...
Botti, Lucia; Mora, Cristina; Regattieri, Alberto
The data presented in this article are related to the research article "Integrating ergonomics and lean manufacturing principles in a hybrid assembly line" (Botti et al., 2017) . The results refer to the application of the mathematical model for the design of lean processes in hybrid assembly lines, meeting both the lean principles and the ergonomic requirements for safe assembly work. Data show that the success of a lean strategy is possible when ergonomics of workers is a parameter of the assembly process design.
Tan Ching Ng
Full Text Available This research aims to ascertain the determinants of effective Lean Manufacturing (LM. In this research, Covariance-based Structural Equation Modeling (CB-SEM analysis will be used in order to analyze the determinants. Through CB-SEM analysis, the significant key determinants can be determined and the direct relationships among determinants can be analyzed. Thus, the findings of this research can act as guidelines for achievement of LM effectiveness, not only providing necessary steps for successful implementation of lean, but also helping lean companies to achieve higher level of lean cost and time savings.
Ivezic, Nenad; Potok, Thomas E.
A method for automatically evaluating a manufacturing technique comprises the steps of: receiving from a user manufacturing process step parameters characterizing a manufacturing process; accepting from the user a selection for an analysis of a particular lean manufacturing technique; automatically compiling process step data for each process step in the manufacturing process; automatically calculating process metrics from a summation of the compiled process step data for each process step; and, presenting the automatically calculated process metrics to the user. A method for evaluating a transition from a batch manufacturing technique to a lean manufacturing technique can comprise the steps of: collecting manufacturing process step characterization parameters; selecting a lean manufacturing technique for analysis; communicating the selected lean manufacturing technique and the manufacturing process step characterization parameters to an automatic manufacturing technique evaluation engine having a mathematical model for generating manufacturing technique evaluation data; and, using the lean manufacturing technique evaluation data to determine whether to transition from an existing manufacturing technique to the selected lean manufacturing technique.
Full Text Available Lean Manufacturing merupakan konsep manufaktur untuk menghasilkan produk yang efisien dengan mengurangi biaya produksi melalui efisiensi. Dalam konsep Lean, dikenal 7 macam pemborosan yang meliputi produksi berlebih, transportasi material yang berlebihan, menunggu, proses yang tidak perlu, persediaan, pergerakan dan cacat produk. Penelitian ini menggunakan value stream mapping dalam mengidentifikasi pemborosan dan menelusuri potensi terjadinya pemborosan. Potensi pemborosan yang terjadi akan direduksi dengan menggunakan instrumen yang sesuai berdasarkan indikator terpilih. Penelitian diharapkan dapat menghasilkan proses produksi yang lebih efisiensi sehingga mampu mereduksi biaya produksi. Pada akhirnya akan menghasilkan profit yang lebih besar. Kata kunci : lean manufacturing, value stream mapping, waste Lean Manufacturing is a manufacturing concepts to produce products that are efficient by reducing production costs through efficiencies. In the Lean concept, known seven kinds of waste, including overproduction, excessive material transportation, waiting, unnecessary processes, inventory, motion and product defects. This study uses value stream mapping to identify waste and exploring the potential for waste. Potential waste that occurs will be reduced by using appropriate instruments based on selected indicators. The study is expected to produce a more efficient production processes so as to reduce production costs.Will ultimately result in greater profits. Keywords: lean manufacturing, value stream mapping, waste
Lucherini, Franco; Rapaccini, Mario
This paper describes the use of simulation and case-study research to assess flexibility gains induced by the adoption of three Lean Manufacturing practices. Design/methodology/approach: We gather useful material and information about the manufacturing process of a selected Small-Medium Enterprise by adopting a case-research approach. The Value Stream Mapping is the method used for visualizing flows of products and information along the production system. Starting from the current arrangement of the company, computer simulation is used to assess the benefits arising from Cellular Manufacturing, Just-in-Time Delivery by Suppliers, and Single Minute Exchange of Dies. Findings: To investigate the flexibility improvements coming from the introduction of Lean Manufacturing, we present a simulation model of the described company on which we performed our analysis. We quantify the flexibility of different configurations according to the new 5-step approach in order to segregate the contribution of different lean techniques. Originality/value: We extend the combined use of Case Research and Computer Simulation to the research on Manufacturing Flexibility within Small-Medium Enterprises. We enhance the knowledge on this under investigated context collecting quantitative field data. Moreover, building on the factorial Design of Experiment, we introduce a new 5-step method to appraise the cost benefit ratio of lean techniques for flexibility. The managerial implication of this research is mostly related to the provision of a supporting method for the decision making process propaedeutic to Lean Manufacturing introduction.
Lucherini, Franco; Rapaccini, Mario
This paper describes the use of simulation and case-study research to assess flexibility gains induced by the adoption of three Lean Manufacturing practices. Design/methodology/approach: We gather useful material and information about the manufacturing process of a selected Small-Medium Enterprise by adopting a case-research approach. The Value Stream Mapping is the method used for visualizing flows of products and information along the production system. Starting from the current arrangement of the company, computer simulation is used to assess the benefits arising from Cellular Manufacturing, Just-in-Time Delivery by Suppliers, and Single Minute Exchange of Dies. Findings: To investigate the flexibility improvements coming from the introduction of Lean Manufacturing, we present a simulation model of the described company on which we performed our analysis. We quantify the flexibility of different configurations according to the new 5-step approach in order to segregate the contribution of different lean techniques. Originality/value: We extend the combined use of Case Research and Computer Simulation to the research on Manufacturing Flexibility within Small-Medium Enterprises. We enhance the knowledge on this under investigated context collecting quantitative field data. Moreover, building on the factorial Design of Experiment, we introduce a new 5-step method to appraise the cost benefit ratio of lean techniques for flexibility. The managerial implication of this research is mostly related to the provision of a supporting method for the decision making process propaedeutic to Lean Manufacturing introduction.
Full Text Available Purpose: This paper describes the use of simulation and case-study research to assess flexibility gains induced by the adoption of three Lean Manufacturing practices. Design/methodology/approach: We gather useful material and information about the manufacturing process of a selected Small-Medium Enterprise by adopting a case-research approach. The Value Stream Mapping is the method used for visualizing flows of products and information along the production system. Starting from the current arrangement of the company, computer simulation is used to assess the benefits arising from Cellular Manufacturing, Just-in-Time Delivery by Suppliers, and Single Minute Exchange of Dies. Findings: To investigate the flexibility improvements coming from the introduction of Lean Manufacturing, we present a simulation model of the described company on which we performed our analysis. We quantify the flexibility of different configurations according to the new 5-step approach in order to segregate the contribution of different lean techniques. Originality/value: We extend the combined use of Case Research and Computer Simulation to the research on Manufacturing Flexibility within Small-Medium Enterprises. We enhance the knowledge on this under investigated context collecting quantitative field data. Moreover, building on the factorial Design of Experiment, we introduce a new 5-step method to appraise the cost benefit ratio of lean techniques for flexibility. The managerial implication of this research is mostly related to the provision of a supporting method for the decision making process propaedeutic to Lean Manufacturing introduction.
Zakaria Nurul Husna
Full Text Available Lean manufacturing is the most convenient way to eliminate unnecessary waste and can provide what customers demand. This paper presents possibilities and sustainability of application of lean manufacturing method by using a virtual simulation of the workers performance in a line production of small and medium industry. Actual case study and Witness simulation were used in this study to find the waste that exists in the production and identified the performance of workers in the production line. Lean manufacturing concept has identified and rectified problems related to low productivity in the assembly line. The case study is involved a line production for electronic part assembly. The result of this preliminary study should illustrate the relationship of worker’s performance by lean manufacturing method as well as the productivity improvements which help to reduce cost for manufacturer. Lean manufacturing method has been used during the study to reduce the cost when waste is eliminated by reducing the workstation without reducing the performance of the production. The performance of the production is increased when allocating the labor in a needed working area. Lastly, the study also proves that the new layout has improved the process to be used for future production process.
Van der Merwe, Karl Robert
Full Text Available Although it is generally accepted that lean manufacturing improves operational performance, many organisations are struggling to adapt to the lean philosophy. The purpose of this study is to contribute to a more effective strategy for implementing the lean manufacturing improvement philosophy. The study sets out both to integrate well-researched findings and theories related to generic organisational culture with more recent research and experience related to lean culture, and to examine the role that culture plays in the effective implementation of lean manufacturing principles and techniques. The ultimate aim of this exercise is to develop a theoretical lean culture causal framework.
Dickson, Eric W; Singh, Sabi; Cheung, Dickson S; Wyatt, Christopher C; Nugent, Andrew S
"Lean" is a set of principles and techniques that drive organizations to continually add value to the product they deliver by enhancing process steps that are necessary, relevant, and valuable while eliminating those that fail to add value. Lean has been used in manufacturing for decades and has been associated with enhanced product quality and overall corporate success. To evaluate whether the adoption of Lean principles by an Emergency Department (ED) improves the value of emergency care delivered. Beginning in December 2005, we implemented a variety of Lean techniques in an effort to enhance patient and staff satisfaction. The implementation followed a six-step process of Lean education, ED observation, patient flow analysis, process redesign, new process testing, and full implementation. Process redesign focused on generating improvement ideas from frontline workers across all departmental units. Value-based and operational outcome measures, including patient satisfaction, expense per patient, ED length of stay (LOS), and patient volume were compared for calendar year 2005 (pre-Lean) and periodically after 2006 (post-Lean). Patient visits increased by 9.23% in 2006. Despite this increase, LOS decreased slightly and patient satisfaction increased significantly without raising the inflation adjusted cost per patient. Lean improved the value of the care we delivered to our patients. Generating and instituting ideas from our frontline providers have been the key to the success of our Lean program. Although Lean represents a fundamental change in the way we think of delivering care, the specific process changes we employed tended to be simple, small procedure modifications specific to our unique people, process, and place. We, therefore, believe that institutions or departments aspiring to adopt Lean should focus on the core principles of Lean rather than on emulating specific process changes made at other institutions.
Virginia, Iuga; Claudiu, Kifor
Manufacturing sectors and companies all over the world are successfully implementing lean principles within their processes. Nowadays, lean has become an indispensable part of global players. Companies worldwide need to be aware of multiple factors which weigh heavily on the success or failure of lean implementation. This paper focuses on giving a brief and structured overview over the fundamental organizational factors which play a substantial role for the lean manufacturing (LM) implementation process. The study below focuses on internal factors which are indispensable for a successful LM implementation within organizations. It is imperative that these internal factors are known, recognized and taken into consideration during the whole LM implementation process. Ignoring their influence on the process's implementation may lead to endangering the expected results or to making the process more difficult which could result in much higher human resource consumption.
Jackson, P R; Mullarkey, S
The impact of lean production on psychological health was assessed by comparing lean production teams in garment manufacture with a traditional system for making similar garments. Work design characteristics were examined as mediators of the impact of work organization on health. Findings indicate both positive and negative direct effects of teamworking on aspects of autonomy, work demands, and social climate. In turn, both positive and negative direct effects of work design on psychological health were found, which combine to give no overall difference between the groups. This study suggests that the balance between positive and negative effects of lean production teamworking depends on management choices in the form of work design.
Puvanasvaran, Perumal; Megat, Hamdan; Hong, Tang Sai; Razali, Muhamad Mohd.
Many companies are implementing lean manufacturing concept in order to remain competitive and sustainable, however, not many of them are successful in the process due to various reasons. Communication is an important aspect of lean process in order to successfully implement lean manufacturing. This paper determines the roles of communication process in ensuring a successful implementation of leanness in manufacturing companies. All the information of lean manufacturing practice...
Low, Kwee Ang
Lean Manufacturing has made a significant impact on both the academic and manufacturing circles in the last decade. Fostered by a rapid spread into many other industrial sectors beyond the automotive industry, there has been significant development and "localisation" of the Lean Manufacturing concept in both developed and developing countries worldwide. Despite its successful application in a wide range of industries, little research has been carried out on its successful application outside ...
Full Text Available Lean Manufacturing has now become a common word in the industrial corridors. It has now been applied to the industries of several domains. No wonder that the Pump manufacturing has also witnessed profound influence of Lean philosophy. Pump manufacturing in India has a history as old as 80 years with more than 500 pump manufacturing units presently working. The present research is an explorative study and was undertaken to identify various factors affecting lean manufacturing implementation in pump manufacturing industry. Analysis of results revealed that the companies registered increase in productivity and reduction in costs and wastes. Lack of understanding, Supply chain and Company culture are found to be the strongest barriers of lean manufacturing implementation. The multiple regression model revealed that Lack of workers support can be fairly reduced by educating them about Lean Manufacturing and establishing a healthy communication with workers. An analysis across different management levels revealed disparity in perceptions and views of personnel. There is a need for top management to align organization toward common goals so as to achieve better success in implementing lean manufacturing.
Full Text Available The goal of this article is to explore the link between lean and green management, reasons for their implementation, their effect throughout the whole life cycle, as well as the current state of use of lean tools, economic and environmental indicators in the context of Croatian manufacturing companies. A semi-structured interview was used in this research. As a result, the frequency of economic and environmental performance indicators and lean tools in Croatian companies has been defined, as well as the reasons for the implementation of lean management. Additionally, the understanding of the use of Life Cycle Assessment methods, environmental standards has been obtained and the integration of lean and green management in Croatian companies has been explored. Further on, results were compared to the similar study done in the UK. Finally, it can be concluded that the integration of lean and green management is not yet sufficiently present in manufacturing companies, although there are cases in which these two approaches are integrated, primarily in the process and food industry. It is for these reasons that in the integration of these two approaches lies great potential.
Full Text Available The lean manufacturing system is a technique of manufacturing products in time. The concept of lean manufacturing principles employs simpler ways of communicating required materials as well as manual technique in ensuring the provision of signals for replenishment of materials the production companies require. Performance on the other hand, can be considered the attainment of value effectively and efficiently. Lean manufacturing and performance production goes hand in hand. Through utilizing lean manufacturing method, most companies would be able to tailor their processes in achieving effective performance and meeting unique requests from their consumers. The exploratory observations conducted in the study was purposely for examining the nature of complex interactions involved between major constructs and environmental sustainability at the parent company and the tire part vendors. The method of the research was a qualitative case study. The research data were obtained from with the case company and through structured interviews the case company's consumers. The case-specific tools were first developed in close co-operation with the case company. Future research agenda addresses gaps in the current literature and suggests relevant framework from which to explore this phenomenon.
The purpose of this paper is to investigate a lean manufacturing metric called Takt time as a benchmark evaluation measure to evaluate a public hospital's service quality. Lean manufacturing is an established managerial philosophy with a proven track record in industry. A lean metric called Takt time is applied as a measure to compare the relative efficiency between two emergency departments (EDs) belonging to the same public hospital. Outcomes guide managers to improve patient services and increase hospital performances. The patient treatment lead time within the hospital's two EDs (one department serves male and the other female patients) are the study's focus. A lean metric called Takt time is used to find the service's relative efficiency. Findings show that the lean manufacturing metric called Takt time can be used as an effective way to measure service efficiency by analyzing relative efficiency and identifies bottlenecks in different departments providing the same services. The paper presents a new procedure to compare relative efficiency between two EDs. It can be applied to any healthcare facility.
Elbadawi, Isam; McWilliams, Douglas L.; Tetteh, Edem G.
Finding appropriate interactive exercises to increase students' learning in technical topic courses is always challenging to educators. In this study, several paper plane hands-on simulation exercises were developed, used, and tested in a lean manufacturing course for beginning college students. A pretest and posttest was used to assess the…
Full Text Available Uniquely positioned as both consumer service providers and tangible finished goods manufacturers, restaurants sell at retail an inventory that is fabricated from raw materials at the site of consumption. This article illustrates how restaurant managers have historically used the fundamentals of just-in-time and lean manufacturing production, often without understanding the power for efficiency and profit each brings. The goal is to encourage restaurateurs to seek a better understanding of where these principles interface with service management theory.
Jorge Viteri Moya
Full Text Available The current industrial competitiveness requires companies to adopt better production methodologies, in order to reduce costs and maximize profits. This is where the adoption of lean manufacturing culture in organizations can generate changes in mentality that focus on free trade of all types of waste, without neglecting the quality. This research aimed to implement the thinking and principles of this philosophy in a food processing company to use resources efficiently, reduce costs and generate higher profits. More than performing a process map and detailed description of key operational processes, three tools of lean manufacturing were used. With 5s was established a clean and orderly work, with the tool just in time waste of different nature including cycle time production decreased; and with VSM the value chain and the new way of working was plotted, without waste.
Rajesh Kumar MEHTA
Full Text Available Lean deals with generating more value for customers by eliminating factors that are merely considered waste. Lean Manufacturing is a systematic approach to identifying and eliminating waste through continuous improvement. Lean Manufacturing uses less of everything and attains its set objectives by excellent teamwork, communication, and competent use of available resources & continuous Improvement. The present paper is an attempt to study employee’s perception towards lean manufacturing systems in gear industry.
Full Text Available The implementation of lean manufacturing concepts has had a significant impact on various industries. Many companies around the world have attempted to implement lean manufacturing, but the lack of an obvious understanding of lean measurement and its performance has caused its implementation to fail. This paper presents an innovative approach by using fuzzy TOPSIS to measure the production leanness of manufacturing systems, as a paradigm. This approach is applied to the Parizan Sanat company.
Full Text Available This article aims to show some factors that can cause companies to succeed or fail in their attempts to use lean manufacturing, by performing a multiple case study which presents two successful cases and three conditions of failure, in a survey of five large companies, all belonging to the metal-mechanical sector, located in Campinas and Sorocaba, both in the state of São Paulo, Brazil. The data were collected using exploratory research between the periods of January 2013 and February 2015. The results show that successful cases of lean manufacturing implementation are the result of a more organized work environment, standardization of production and service areas, employee satisfaction, productivity results and quality of the final product. Unsuccessful deployments result from poor execution and faulty planning, that has no benefit and ultimately decrease the morale of its employees, creating more distrust and frustration directly influencing the results and productivity. In other words, lean manufacturing implementation requires hard and continuous work and these procedures should be aligned with the mission and goals of companies and mainly focus on the maintenance result by using tools to monitor and track the process systematically and also making investments to eliminate waste.
Pinto, Marcos José Alves Junior; Mendes, Juliana Veiga
Purpose: The objective of this paper is to investigate how environmental improvements can be achieved through operational practices of Lean Manufacturing. Design/methodology/approach: A literature review was conducted to analyze the relationship between operational practices of Lean and reduction of environmental impact in organizational contexts. Verified theoretically, this relationship was observed in a company of the electronics industry, through an exploratory research which contemplated a mixed approach. The adopted research method consisted of a single case study, by providing greater depth and detail of the study. Utilized a research protocol, validated test pilot. The instruments for data collection were semi-structured interviews, direct observation and document analysis. The information was examined qualitatively considering the technique for content analysis. Findings: As a result of the study, it was found that there is evidence for the existence of relationship between the practices of Lean, for example, Kaizen, PDCA (plan, do, check, act), Ishikawa Diagram, Poka-Yoke, Standardized Work and Value Stream Mapping, with the reduction of environmental impacts of an organization. This reduction was observed after application of these practices that resulted in the reduction of energy consumption, water and waste generation. These results were accounted for financially, contributing to a reduction of annual costs by about US$ 20,900. Originality/value: The study presents in detail, the application of operational practices of Lean Manufacturing, with an effective view to reducing the environmental impact and cost reduction. The literature review, a detailed description of the application process and financial results are important information that contributes to the scientific studies that address traditional operating practices and the search for better environmental performance.
Marcos José Alves Pinto Junior
Full Text Available Purpose: The objective of this paper is to investigate how environmental improvements can be achieved through operational practices of Lean Manufacturing. Design/methodology/approach: A literature review was conducted to analyze the relationship between operational practices of Lean and reduction of environmental impact in organizational contexts. Verified theoretically, this relationship was observed in a company of the electronics industry, through an exploratory research which contemplated a mixed approach. The adopted research method consisted of a single case study, by providing greater depth and detail of the study. Utilized a research protocol, validated test pilot. The instruments for data collection were semi-structured interviews, direct observation and document analysis. The information was examined qualitatively considering the technique for content analysis. Findings: As a result of the study, it was found that there is evidence for the existence of relationship between the practices of Lean, for example, Kaizen, PDCA (plan, do, check, act, Ishikawa Diagram, Poka-Yoke, Standardized Work and Value Stream Mapping, with the reduction of environmental impacts of an organization. This reduction was observed after application of these practices that resulted in the reduction of energy consumption, water and waste generation. These results were accounted for financially, contributing to a reduction of annual costs by about US$ 20,900. Originality/value: The study presents in detail, the application of operational practices of Lean Manufacturing, with an effective view to reducing the environmental impact and cost reduction. The literature review, a detailed description of the application process and financial results are important information that contributes to the scientific studies that address traditional operating practices and the search for better environmental performance.
Pinto, Marcos José Alves Junior; Mendes, Juliana Veiga
Purpose: The objective of this paper is to investigate how environmental improvements can be achieved through operational practices of Lean Manufacturing. Design/methodology/approach: A literature review was conducted to analyze the relationship between operational practices of Lean and reduction of environmental impact in organizational contexts. Verified theoretically, this relationship was observed in a company of the electronics industry, through an exploratory research which contemplated a mixed approach. The adopted research method consisted of a single case study, by providing greater depth and detail of the study. Utilized a research protocol, validated test pilot. The instruments for data collection were semi-structured interviews, direct observation and document analysis. The information was examined qualitatively considering the technique for content analysis. Findings: As a result of the study, it was found that there is evidence for the existence of relationship between the practices of Lean, for example, Kaizen, PDCA (plan, do, check, act), Ishikawa Diagram, Poka-Yoke, Standardized Work and Value Stream Mapping, with the reduction of environmental impacts of an organization. This reduction was observed after application of these practices that resulted in the reduction of energy consumption, water and waste generation. These results were accounted for financially, contributing to a reduction of annual costs by about US$ 20,900. Originality/value: The study presents in detail, the application of operational practices of Lean Manufacturing, with an effective view to reducing the environmental impact and cost reduction. The literature review, a detailed description of the application process and financial results are important information that contributes to the scientific studies that address traditional operating practices and the search for better environmental performance.
Hussein Salem Ketan
Full Text Available Many organizations today are interesting to implementing lean manufacturing principles that should enable them to eliminating the wastes to reducing a manufacturing lead time. This paper concentrates on increasing the competitive level of the company in globalization markets and improving of the productivity by reducing the manufacturing lead time. This will be by using the main tool of lean manufacturing which is value stream mapping (VSM to identifying all the activities of manufacturing process (value and non-value added activities to reducing elimination of wastes (non-value added activities by converting a manufacturing system to pull instead of push by applying some of pull system strategies as kanban and first on first out lane (FIFO. ARENA software is used to simulate the current and future state. This work is executed in the state company for electrical industries in Baghdad. The obtained results of the application showed that implementation of lean principles helped on reducing of a manufacturing lead time by 33%.
Juan A. Marin-Garcia
Full Text Available In the last 30 years of research of lean manufacturing many different questionnaires was proposed to check the degree of the use of the concept. The set of the items used changed considerably from one investigation to another one. Until now isn’t appreciate a movement that converge towards the use, by the investigators, of a few instruments whose validity and reliability have been compared in different surroundings. In fact, the majority of investigations are based on ad-hoc questionnaires and a few of them present the questionnaire validation checking only the unidimensionality and -Cronbach. Nevertheless it seems to have a consensus in identifying 5 big constructs that compose the lean manufacturing (TQM, JIT, TPM, supply chain management and high-involvement. Our research has consisted of identifying and summarizing the models that have been published previously to add the items in constructs or sub-scales of constructs. Later we developed an integrating questionnaire, starting off of the items that appeared in previous investigations. Finally we realized the sub-scales and models validation through a confirmatory factorial analysis, using date of a sample of Spanish Sheltered Work Centre’s (N=128. Of all proposed models, the best an adjustment takes place with the first order model with 20 sub-scales. Our investigation contributes to an integrating vision of the published models and the lean manufacturing sub-scales validity and reliability verification raised by other investigators. Due to his confirming approach, it can serve as generalization of studies that had been realized in contexts with different samples to which we have used for the replication.
Full Text Available One of the big investment in a business is facility design. It is a long-term investment due to great value. In its development, PT. Dwi Putra Sakti faced some problems related to facility layout. Problems that can be identified, such as work in process that has accumulated on the production floor, as well as the anorganizad facility layout. Therefore, it is necessary to redesign the layout for the production process more effective and efficient. This study uses a lean manufacturing approach to redesign facility layout. It used value stream mapping, seven waste, cellular manufacturing and 5S principle. Analysis of the implementation result is used to design the layout of the new facility. Level layout that will be examined are the macro-and micro-layout layout. Results of macro-layout design is decreasing production cycle time of trousers. While the micro-layout design is decreasing in material handling displacement.
Full Text Available Many companies are implementing lean manufacturing concept in order to remain competitive and sustainable, however, not many of them are successful in the process due to various reasons. Communication is an important aspect of lean process in order to successfully implement lean manufacturing. This paper determines the roles of communication process in ensuring a successful implementation of leanness in manufacturing companies. All the information of lean manufacturing practices and roles of communication in the implementation were compiled from related journals, books and websites. A study was conducted in an aerospace manufacturing in Malaysia. A five-point scale questionnaire is used as the study instrument. These questionnaires were distributed to 45 employees working in a kitting department and to 8 top management people. The results indicate that the degree of leanness were moderate.
Ozelkan, Ertunga C.; Teng, S. Gary; Johnson, Thomas; Benson, Tom; Nestvogel, Dean
With the ongoing global pressure to cut costs and focus on quality, many companies have been implementing "lean manufacturing" concepts to survive in the competitive marketplace. Thus it is imperative that engineering and business graduates are equipped with the lean principles, and are ready to take ownership of lean initiatives as they enter the…
Rasi, Raja Zuraidah R. M.; Syamsyul Rakiman, Umol; Ahmad, Md Fauzi Bin
Nowadays, more and more manufacturing firms have started to implement lean production system in their operations. Lean production viewed as one of the mechanism to maintain the organisation's position and to compete globally. However, many fail to apply the lean concepts successfully in their operations. Based on previous studies, implementation of lean production in the manufacturing industry is more focused on the relationship between Lean and Operational Performance of one dimension only. Therefore, this study attempted to examine the relationship between Lean Production (LP) and Operational Performance in 4 dimensions which are quality, delivery, cost and flexibility. This study employed quantitative study using questionnaires. Data was collected from 50 manufacturing industries. The data was analysed using Statistical Package for Social Science (SPSS) 22.0. This study is hoped to shed new understanding on the concept of Lean Production (LP) in regards of Operational Performance covering the 4 dimensions.
Lean og Agile (Leagile) Manufacturing indebærer ikke blot den rette balance (dekobling) mellem lean producerede komponenter og agile konfigurerede færdigvarer, og dermed til levering af individualiserede produkter til konkurrencedygtige priser og høj kvalitet, men også til effektivitet og...... fleksibilitet i produktudvikling og produktion. For at opnå integrationen mellem agile og lean kan der arbejdes med en vifte af integrationsmekanismer inden for organisatoriske og teknologiske virkemidler. Projektet har til formål at identificere, strukturere og modellere de centrale analyse- og...
Full Text Available The hypothesis that lean manufacturing audits are an effective way to measure improvements in operational performance was tested using 64 manufacturing sites owned by a FTSE 100 company. Commonly-used lean characteristics were evaluated: policy deployment, standardised work, visual management and housekeeping, quick changeover techniques, total productive maintenance, continuous improvement (kaizen, error proofing, cultural awareness, material control, and levelling (heijunka. Operational performance was assessed employing commonly-used operational performance measures: on-time-delivery, inventory turns, and direct labour utilisation. The findings are that lean manufacturing audits are effective in measuring improvements in operational performance provided that the audit scope and the lean characteristics are aligned up front.
Energy efficiency has become a competitive issue for industrial companies. The evolution of energy prices and regulation will make this issue even more important in the future. For several years, the energy-intensive chemical industry has been implementing corrective actions. Helped by the absorption of base load energy consumption by larger production volumes, specific energy consumption (KWh per production unit) has been significantly reduced in recent years. However, most plants have reached the end of their first action plan based on improving the utilities performance. The Leanergy(TM) method developed by the consultancy company Okavango-energy, is a structured approach based on lean manufacturing which widens the scope of saving sources to process and operations. Starting from the analysis of actual production requirements, Okavango is able to adjust consumption to minimum requirements and so remove any energy consumption that does not contribute to the added value creation.
Full Text Available This paper gives an overview of a 9 month experience in implementing lean manufacturing tools in two Serbian food companies. Both companies have certified quality and food safety management systems and are food exporters. One of them is a big producer with more than 1000 employees with a three shift serial production while the other is a small producer with one shift and batch oriented production. Results showed that six tools were chosen by both companies - Total productive maintenance, Poka yoke, batch reduction, layout improvement, standardization of work and visual management. The big company implemented also cellular and flow, Jidoka, quick changeovers and 5S. None of the companies expressed interest at implementing Just-In-Time, Kanban, Self-inspection and Value stream mapping at this stage of the project.
Farah Widyan Hazmi
Full Text Available PT ARISU merupakan perusahaan job order yang menghasilkan packaging dalam bentuk lembaran, roll dan tube. PT ARISU berusaha untuk selalu meningkatkan keunggulannya agar dapat bersaing. Peningkatan keunggulan ini dilakukan dengan salah satu caranya adalah dengan meminimasi waste (pemborosan. Selama proses produksi terjadi adanya pemborosan antara lain inappropriate processing, unnecessary inventory, waiting dan defect. Lean Manufacturing merupakan pendekatan yang bertujuan untuk meminimasi pemborosan yang terjadi pada aliran proses produksi. Pemborosan tersebut akan dicari akar penyebabnya menggunakan root cause analysis. Setelah diketahui akar penyebabnya maka dilakukan perhitungan risk rating menggunakan analisa resiko untuk mengetahui akar penyebab yang paling berpotensial. Kemudian dilakukan pemilihan alternatif usulan perbaikan dengan empat alternatif usulan perbaikan yang dapat dipilih antara lain adanya tanda atau label peringatan pada setiap station, pelatihan mengenai autonomous maintenance, pembuatan mesin harian yang terjadwal dan adanya red taggimg. Pada pemilihan usulan alternatif perbaikan didapatkan usulan alternatif perbaikan terbaik adalah menyelenggarakan pelatihan autonomous maintenance dan pembuatan mesin harian yang terjadwal.
van der Steen, Martijn; Tillema, Sandra
Purpose: This paper addresses the impact of a multidivisional structure on the implementation of lean manufacturing. It investigates how the controls employed by the corporate level impact the local implementation of lean manufacturing. Design/methodology/approach: The paper reports on case studies
Ibrahim, Wan Mohd Khairi bin Wan; Rahman, Mohamed Abdul; Abu Bakar, Mohd Rushdi bin
Domestic pharmaceutical industry has been identified by the Malaysian government as an industry to be developed under its 11th economic development plan. Most homegrown pharmaceutical companies fall under the category of small and medium enterprises (SME) and therefore need to be highly efficient in their operations to compete with the multinationals. Though lean manufacturing is a well-known methodology to achieve an efficient operation, only a small percentage of the local SMEs implement it. The study aims to determine the real success factors in lean implementation through systematic review of relevant literature on lean manufacturing implementation in local companies, onsite observation of a selected SME company, Global Factor Sdn. Bhd. (GFSB), that successfully implemented lean manufacturing followed by actual implementation of lean project at IKOP Sdn. Bhd., a small startup pharmaceutical company. Lean tools like Gemba, value stream map (VSM) and spaghetti diagram were used to analyze and improve a process at IKOP Sdn. Bhd. The literature review showed that the implementation of lean manufacturing at Malaysian SMEs involved in pharmaceutical industry is at its infancy. Study at GFSB indicated that successful implementation of lean manufacturing stems from management support, employee’s commitment, government support and knowledge on lean among employees. Application of lean tools in IKOP Sdn. Bhd. to improve the process cycle efficiency of hand sanitizer, i-Hand 4.0, has shown that the GMP guidelines are not jeopardized. The Kaizen improvement project resulted in 46.3% reduction in lead time. It may be concluded that implementing lean manufacturing in any small local startup pharmaceutical company is beneficial in reducing operational costs and increasing the efficiency and effectiveness and does not conflict with the existing GMP guidelines.
Alaa, A. S.; Shaiful, A. I. M.; Zuraidah, M. Z.; Khalaf, A. M.
Nowadays, lean manufacturing strategy is very much used to eliminate waste on the manufacturing shop floor. Lean manufacturing has been formulated in response to the fluctuating and competitive business environment. Although it first started in the automotive industry, many organizations in different sectors are enthusiastic to adopt it in order to improve their performance in this competitive globalized market. The aim of this paper is to review the current level of implementation of lean manufacturing practices and the affects of these practices on organizational performances in a multitude of sectors in Malaysian industries. The study is carried out through a thorough review of the literature. It is observed that lean manufacturing is increasingly getting the appropriate attention in Malaysian industries. There are also many challenges in the way, of which numerous attempts are undertaken to overcome them.
Full Text Available Lean manufacturing provides a new management approach for many small and medium size manufacturers, especially older firms organized and managed under traditional push systems. Improvement results can be dramatic in terms of quality, cycle times, and customer responsiveness. Lean manufacturing is more than a set of tools and techniques and has been widely adopted by many production companies. Lean manufacturing is a culture in which all employees continuously look for ways to improve processes. In the present article are presented the Lean Manufacturing tools, like kaizen, Kanban, poka-yoke witch a company can use to reduce the waste(muda during a production process. The paper contains also, the most common seven types of waste from production and some examples from our daily activity.
Full Text Available At the work were introduced main areas of production system project of casts produced in permanent moulds, that constitutes reengineering of conventional production system according to Lean Manufacturing (LM methods. New resolution of cooling of dies with water mist was shown to casting of car wheels made from aluminium alloys in low pressure casting process. It was implemented as a part of goal-oriented project in R.H. Alurad Sp.z o.o. in Gorzyce. Its using intensifies solidification and self-cooling of casts shortening the time of casting cycle by the 30%. It was described reorganizing casting stations into multi-machines cells production and the process of their fast tool’s exchange with applying the SMED method. A project of the system was described controlling the production of the foundry with the computer aided light Kanban system. A visualization of the process was shown the production of casts with use the value stream mapping method. They proved that applying casting new method in the technology and LM methods allowed to eliminate down-times, to reduce the level of stocks, to increase the productivity and the flow of the castings production.
Siregar, Ikhsan; Arif Nasution, Abdillah; Prasetio, Aji; Fadillah, Kharis
This research was conducted on the company engaged in the production of Fast Moving Consumer Goods (FMCG). The production process in the company are still exists several activities that cause waste. Non value added activity (NVA) in the implementation is still widely found, so the cycle time generated to make the product will be longer. A form of improvement on the production line is by applying lean manufacturing method to identify waste along the value stream to find non value added activities. Non value added activity can be eliminated and reduced by utilizing value stream mapping and identifying it with activity mapping process. According to the results obtained that there are 26% of value-added activities and 74% non value added activity. The results obtained through the current state map of the production process of process lead time value of 678.11 minutes and processing time of 173.94 minutes. While the results obtained from the research proposal is the percentage of value added time of 41% of production process activities while non value added time of the production process of 59%. While the results obtained through the future state map of the production process of process lead time value of 426.69 minutes and processing time of 173.89 minutes.
Approximately 80% of lean manufacturing program initiatives are abandoned in the first year of implementation. Only 2% of organizations that embark on the lean journey complete it with the results and the sustainability they expected. There is a gap in past research regarding, the leadership strategies organizations can use to overcome resistance…
.... Largely in response to these measures, U.S. defense firms have in recent years begun to embrace lean manufacturing, a broad collection of principles and practices whose aim is to refashion the production process in a manner that includes...
Florida hospital saves 5.3M dollars by adopting principles of lean manufacturing. Surgery cancellations have been slashed from 13% of cases to less than 3%, while emergency department admissions have increased by 20%. Those are just two of the results of a quality improvement project at Lee Memorial Health System in Fort Myers, FL, that focused on using the principles of lean manufacturing to improve patient flow in the five-hospital system
Dana Marsetiya Utama
Full Text Available This study discusses lean manufacturing concept to identify waste in Key Set Clarinet production process at Yamaha Musical Products Indonesia, Ltd. The lean manufacturing concept is done intially by big picture mapping, waste assessment model (WAM, value stream mapping (VSM and cause and effect diagram respectively. The results show that the dominant waste is defect (26.04%, motion (19.34%, inventory (19.22%, and waiting (13.91%.
AÑAGUARI YARASCA, MILUSKA AYLIN; Gisbert Soler, Víctor
[EN] This article, based on previous studies and multiple written literature, aims to raise awareness of the importance of the implementation of lean manufacturing tools in the Spanish industrial SMEs, showing which are the critical factors that directly affect the performance competitive SMEs today. As well as raise awareness of Lean Manufacturing, strategies for implementation and the benefits this brings to the company. [ES] El presente artículo, en base a estudios previos y a la múltip...
Sarria Yépez, Mónica Patricia; Fonseca Villamarín, Guillermo Alberto; Bocanegra-Herrera, Claudia Cristina
Resumen Se diseñó una metodología flexible de implementación de lean manufacturing dirigido a empresas industriales, que partió de los modelos teóricos existentes. Se utilizó la metodología ICOM que permite determinar las relaciones entre los procesos y la construcción del diagrama de contexto de manera que la implementación de lean manufacturing sea más fácil de entender por las empresas. Se revisaron los principales métodos de implementación de diferentes autores que escriben sobre lean man...
Hilburn, Monty D.
Successful lean manufacturing and cellular manufacturing execution relies upon a foundation of leadership commitment and strategic planning built upon solid data and robust analysis. The problem for this study was to create and employ a simple lean transformation planning model and review process that could be used to identify functional support staff resources required to plan and execute lean manufacturing cells within aerospace assembly and manufacturing sites. The lean planning model was developed using available literature for lean manufacturing kaizen best practices and validated through a Delphi panel of lean experts. The resulting model and a standardized review process were used to assess the state of lean transformation planning at five sites of an international aerospace manufacturing and assembly company. The results of the three day, on-site review were compared with baseline plans collected from each of the five sites to determine if there analyzed, with focus on three critical areas of lean planning: the number and type of manufacturing cells identified, the number, type, and duration of planned lean and continuous kaizen events, and the quantity and type of functional staffing resources planned to support the kaizen schedule. Summarized data of the baseline and on-site reviews was analyzed with descriptive statistics. ANOVAs and paired-t tests at 95% significance level were conducted on the means of data sets to determine if null hypotheses related to cell, kaizen event, and support resources could be rejected. The results of the research found significant differences between lean transformation plans developed by site leadership and plans developed utilizing the structured, on-site review process and lean transformation planning model. The null hypothesis that there was no difference between the means of pre-review and on-site cell counts was rejected, as was the null hypothesis that there was no significant difference in kaizen event plans. These
Lean production changes organizational style and structure, roles of team leaders and members, training needs, problem-solving approaches, labor relations, and pay practices. The profound cultural changes it causes may trigger defenses that cause it to fail. (SK)
Kane, Marlena; Chui, Kristen; Rimicci, Janet; Callagy, Patrice; Hereford, James; Shen, Sam; Norris, Robert; Pickham, David
A multidisciplinary team led by nursing leadership and physicians developed a plan to meet increasing demand and improve the patient experience in the ED without expanding the department's current resources. The approach included Lean tools and engaged frontline staff and physicians. Applying Lean management principles resulted in quicker service, improved patient satisfaction, increased capacity, and reduced resource utilization. Incorporating continuous daily management is necessary for sustainment of continuous improvement activities.
Iris, Cagatay; Cebeci, Ufuk
with rapid development of information technology (IT) and progress in modern production management strategies have emerged. Obtained results show that Turkish SMEs have widely initiated lean production practices. However, applications are in initial level in the most cases. In respect to ERP systems...... is not adequate to make an inference about relationship between ERP and lean practices. Hence, a relational model is developed to analyze correlation between use of ERP and lean manufacturing implementation in white goods manufacturing SMEs of Istanbul, Turkey. Design/methodology/approach - The examination......Purpose - The purpose of this paper is to understand how effective Turkish small and medium size enterprises (SMEs) use enterprise resource planning (ERP) systems in module aspect and to assess the adherence to lean manufacturing requirements. Obtaining each efficiency result separately...
Full Text Available In this competitive era, manufacturing enterprises struggle to adopt cost-effective manufacturing systems. Overview of the recent manufacturing enterprises shows that successful global manufacturing enterprises have distributed their manufacturing capabilities over the globe. The successes of distributed integrated manufacturing enterprises depend upon the adaptation of appropriate manufacturing technologies like computer integrated manufacturing (CIM under the global collaborative environment along with the principles of lean manufacturing so that their corporate goals are achieved. CIM is an umbrella term which involves automated design, analysis, planning manufacturing, dispatching, customer-interaction, purchasing, cost accounting, inventory control and factory floor functions, which are inter-linked through the computer, to control all the campus-wide manufacturing related operations. It helps to improve the performance of a firm by integrating various areas of manufacturing business in which most of lean ideas are embedded. These lean ideas cause work in a process to be performed with minimum of non-value adding activities and focus on customers’ needs by delivering them at minimum time, with high quality and at minimum cost by eliminating hidden waste. What happens at the shop floor of even an integrated industry is that proper and timely attention is not paid to the intangible lean principles in the manual part of the CIM system which results in substantial loss of the plant productivity. Therefore the objective of this research paper is to investigate the different poor productivity-related problems in a partially integrated manufacturing environment and lay down the remedial measures to eradicate them using ‘Juran’s problem solving techniques’ and various ‘lean tools’ which results in the reduced wastages and hence improved productivity.
Giuliano Almeida Marodin
Full Text Available This article aims to investigate how of lean production (LP influences to a manufacturing cell (MC performance, based on the theoretical study about the attributes that characterize a MC. It was necessary to develop the concept of MC in a socio-technical system perspective, incorporating a technical attribute, a social attribute and the elements of time, space and information to define a "real cell". The results show that most of LM practices aim to increase time and information. The rapid problem solving process and the use of minimal amount of inventory between the activities of the cell seeks to simultaneously reduces the processing time and increase the degree of information. Although influenced to a lesser degree, the organizational attribute and space element are also positively influenced by the practical application of PE.
Rishi J. P.
Full Text Available Lean Manufacturing is a way to deal with the elimination of waste through persistent change within the system. The assembling units in India should likewise hope to take its preferences. The Industries are energetically following the Lean assembling strategies to reduce waste and cost. The present work is the study of a manufacturing process for axle housing and to decide how Lean manufacturing process carried out for axle housing plant to improve productivity. The new shot peening machine was installed in a heat treatment plant of a housing line in an automobile rear axle assembly plant and material handling time from storage to this new machine was more and this increased lead time subsequently. To reduce this Kaizens technique was employed and a direct gravity conveyor was chosen and installed between two work stations and the part was directly fed to the new machine installed and this reduces the material handling time considerably. A cost analysis was done to realize the benefits of implementing this lean technique. Therefore reducing lead time and increasing productivity is the Prime benefits of lean manufacturing practices like lean assembly.
En fatwa i Saudi Arabien om, at en kvinde kan amme en voksen mand for at undgå seksuelle forhold mellem de to.......En fatwa i Saudi Arabien om, at en kvinde kan amme en voksen mand for at undgå seksuelle forhold mellem de to....
Badurdeen, Fazleena; Marksberry, Philip; Hall, Arlie; Gregory, Bob
Problem-based learning focuses on small groups using authentic problems as a means to help participants obtain knowledge and problem-solving skills. This approach makes problem-based learning ideal for teaching lean manufacturing, which is driven by a culture of problem solving that values learning as one key output of manufacturing production.…
This dissertation investigates the impact of radio frequency identification (RFID) in manufacturing. Two simulation studies of an organization that is considering implementing RFID on a production line are conducted. First, we investigate whether addition of RFID technologies in the manufacturing process can complement Lean initiatives.…
Bogen tager udgangspunkt i en undersøgelse af 10 private og offentlige virksomheders erfaringer med lean. Undersøgelsen viser at der ikke findes entydige sammenhænge mellem lean og det psykosociale arbejdsmiljø. Bogen forholder sig til sammenhængen mellem lean og ledelse, lean og medarbejderens...... rolle, lean og lean og forandringsprocessen. Bogen kommer desuden med anbefalinger til hvorledes virksomheden kan gribe dialogen an for at opnå et godt lean forløb der inddrager hensynet til og effekterne af et godt psykosocialt arbejdsmiljø....
Teo, I Jyn Alvin
Companies today constantly seek to lower costs, maintain high level of quality and improve delivery for both manufactured products and services to achieve and sustain competitive advantage. Most companies seek to achieve all this through the implementation of continuous improvement initiatives. Amongst the various continuous improvement initiatives, Lean and Six Sigma have been the most popular and widely adopted. In recent years, the term Lean Six Sigma has been used to describe a management...
ZHAO, QIAN; ZHOU, BOWEN
Introduction: To improvement the target company’s manufacturing process by applyinglean principles, including using and analyzing the internal value stream mapping. Asmore and more companies have paid attention to implement lean thinking in theirmanufacturing process, the value stream mapping played an important role for manycompanies to make a transition from their traditional production systems to lean systems.The content and resources of this master thesis come from an American furnitureco...
Aminuddin, Adam Shariff Adli; Nawawi, Mohd Kamal Mohd; Mohamed, Nik Mohd Zuki Nik
Sustainable manufacturing is regarded as the most complex manufacturing paradigm to date as it holds the widest scope of requirements. In addition, its three major pillars of economic, environment and society though distinct, have some overlapping among each of its elements. Even though the concept of sustainability is not new, the development of the performance indicator still needs a lot of improvement due to its multifaceted nature, which requires integrated approach to solve the problem. This paper proposed the best combination of criteria en route a robust sustainable manufacturing performance indicator formation via Analytic Network Process (ANP). The integrated lean, green and sustainable ANP model can be used to comprehend the complex decision system of the sustainability assessment. The finding shows that green manufacturing is more sustainable than lean manufacturing. It also illustrates that procurement practice is the most important criteria in the sustainable manufacturing performance indicator.
Full Text Available Lean manufacturing belongs to the basic philosophies originating in automotive industry. It was originally based on a number of elementary principles and methods. Companies from other industrial areas have also been gradually trying to apply these principles. This leads to the incorporation of other tools from various areas into this concept. The fundamental techniques of lean manufacturing include the hourly stability (output analysis. This method can be applied in a wide variety of manufacturing fields. The aim is a stable working worker, not a worker working rapidly and with large fluctuations. Speed and sudden changes mean inaccuracy, poor quality and problems to the manufacturing companies. The research has also carried out the hourly stability analysis in a company manufacturing components for a variety of global car manufacturers. The objective of this article is to evaluate the research of hourly stability for the selected workplaces.
Full Text Available To be successful in global competition, the number of firms adopted lean manufacturing systems are increasing every day. Traditional cost management systems is insufficient to produce the information needed for businesses adopting lean manufacturing system. Value stream costing system, appropriate for lean manufacturing enterprises’s value stream organization, better serves the purpose of lean enterprises. In this study value stream costing introduced and selection of costing system for lean manufacturing environments will be done.
Rudy Indra Purnama
Full Text Available Industri farmasi sedang menghadapi persaingan yang meningkat, tekanan biaya dan kebutuhan untuk meningkatkan kinerja operasi manufakturnya. Lean manufacuring menawarkan metode, alat dan program heuristik untuk peningkatan produktivitas di bidang manufaktur. PT. US di Jawa Barat dapat meningkatkan kinerja perusahaannya melalui Lean manufacuring. Penelitian ini bertujuan meningkatkan produktivitas dengan mengidentifikasi dan menyeimbangkan proses kerja dan meneliti penyebab lamanya cycle time melalui value stream mapping. Penelitian ini menghasilkan penurunan cycle time dari 538,96 detik menjadi 445,68 detik, penurunan personel 14 orang, penurunan biaya operasional man power Rp.18,2 juta per bulan, dan menurunkan lead time dari 14,5 hari menjadi 11,5 hari. Kata kunci: lean manufacturing, keseimbangan lini, peningkatan kapasitas, tact time, value stream mapping Abstract The pharmaceutical industry is facing increased competition, cost pressures and the need to improve the performance of its manufacturing operations. Lean manufacturing offer methods, tools and heuristic program for increasing productivity in manufacturing. PT. US in West Java, Indonesia can improve company performance with implementing Lean manufacturing. This study aims to improve productivity by identifying and balancing work and researching the causes of long cycle time with value stream mapping. This research resulted in a decrease cycle time of 538.96 seconds to 445.68 seconds, a decrease of 14 personnel, operating expenses decreased man power Rp.18, 2 million per month, and reduce the lead time of 14.5 days to 11.5 days . Key words: lean manufacturing, line balancing, capacity building, tact time, value stream mapping
Full Text Available The purpose of this paper is to explore and integrate the role of human resources with the internal practices of the Indian manufacturing industries towards successful implementation of lean manu-facturing (LM. An extensive literature survey is carried out. An attempt is made to build an ex-haustive list of all the input manifests related to human resources and internal practices necessary for LM implementation, coupled with a similar exhaustive list of the benefits accrued from its suc-cessful implementation. A structural model is thus conceptualized, which is empirically validated based on the data from the Indian manufacturing sector. Hardly any survey based empirical study in India has been found to integrate human resources with the internal processes towards success-ful LM implementation. This empirical research is thus carried out in the Indian manufacturing in-dustries. The analysis reveals six key input constructs and three output constructs, indicating that these constructs should act in unison to maximize the benefits of implementing lean. The structural model presented in this paper may be treated as a guide to integrate human resources with internal practices to successfully implement lean, leading to an optimum utilization of resources. This work is one of the very first researches to have a survey-based empirical analysis of the role of human resources and internal practices of the Indian manufacturing sector towards an effective lean im-plementation.
Scott, Fiona M.; Butler, Jim; Edwards, John
An action learning program was implemented by a manufacturer using lean production practices. Action learning practices were accommodated during times of stability, but abandoned in times of crisis. The meaning of work in this organizational culture excluded all practices, such as reflection, that were not visible and targeted at immediate…
Flumerfelt, Shannon; Siriban-Manalang, Anna Bella; Kahlen, Franz-Josef
Purpose: This paper aims to peruse theories and practices of agile and lean manufacturing systems to determine whether they employ sustainability, complexity and organizational learning. Design/methodology/approach: The critical review of the comparative operational similarities and difference of the two systems was conducted while the new views…
Cullinane, S.J.; Bosak, J.; Flood, P.; Demerouti, E.
The implications of lean manufacturing for employee well-being remain unclear as previous research yields conflicting findings and struggles to identify an applicable model of job design. This paper adapts and integrates both the job characteristics model and the job demands–resources model to
van der Zee, DJ; Slomp, J; Kuhl, M.E.; Steiger, N.M.; Armstrong, F.B.; Joines, J.
In this article we illustrate how simulation and gaming can be used to support lean manufacturing systems. More in particular we study a case example from industry - a manual assembly line for mail-inserting systems - for which we have developed a simulation game. This paper focuses on the
Timans, W.; Antony, J.; Ahaus, K.; van Solingen, R.
In this paper we provide an exploration and analysis of Lean Six Sigma (LSS) implementation in Dutch manufacturing/engineering small- and medium-sized enterprises (SMEs). Critical success factors (CSFs) and impeding factors are identified and analysed. Exploratory empirical evidence about LSS
Bokhorst, Jos A. C.; Slomp, Jannes
Eaton Electric General Supplies, a parts manufacturing unit that supplies parts for Eaton's electrical business unit, implemented several lean control elements in its high-variety, low-volume production units. These control elements include a constant work-in-process mechanism to limit and control
Tetteh, Edem; McWilliams, Douglas
Customer needs for high-quality goods and the risk of product-liability litigation against businesses have made companies look for a way to sustain quality assurance in their products and services. Lean manufacturing is the latest and most successful system being used by companies to turn their business around. Visual inspection plays an important…
Adrian Pirraglia; Daniel Saloni; Herman van Dyk
Lean Manufacturing has helped several industries to achieve operational and manufacturing excellence by increasing productivity and enhancing quality, while reducing waste and costs. However, the wood industry has been historically slow in adopting this philosophy and its many tools. In times when overseas competition has taken big portions of the traditional market share for U.S based wood industries, it has become important that companies start to take actions in order to regain competitive...
Rampasso, Izabela Simon; Anholon, Rosley; Gonçalves Quelhas, Osvaldo Luiz; Filho, Walter Leal
Lean philosophy is used by companies to increase productivity and reduce costs. Although uncontested benefits are created, it is necessary to highlight the problems related to employees' health and welfare caused by implementing lean manufacturing projects. The primary objective of this paper is to review the literature and identify the most relevant problems created by lean philosophy for employees. Research about the theme was performed on many international databases over three months, and an initial sample of 77 papers was found. Twenty-seven sources were utilized. We identified 22 categories of problems related to health and welfare of employees. The most cited problem was work intensification, mentioned by thirteen papers. Increased stress and increased responsibilities, demands and, consequently, pressure on the workers are among the primary problems observed in the research.
Brown, Garrett D; O'Rourke, Dara
Lean manufacturing, which establishes small production "cells," or teams of workers, who complete an entire product from raw material processing through final assembly and shipment, increases health and safety hazards by mixing previously separated exposures to various chemicals (with possible additive and cumulative effects) and noise. The intensification of work leads to greater ergonomic and stress-related adverse health effects, as well as increased safety hazards. The standard industrial hygiene approach of anticipation, recognition, evaluation, and hazard control is applicable to lean operations. A focus on worker participation in identifying and solving problems is critical for reducing negative impacts. A key to worker safety in lean production operations is the development of informed, empowered, and active workers with the knowledge, skills, and opportunity to act in the workplace to eliminate or reduce hazards.
Full Text Available Lean is a powerful tool, which can bring significant benefit to manufacturing industries by creating value through reduction of waste. Although the lean concept has become very popular in mass production industries such as the automotive industry, more recently the concept has been adopted in different batch processing industries and service sectors. The application of lean tools into the food processing industry has not received the same level of attention compared to the traditional manufacturing industries. The paper discusses how the lean concept could be applied to a fish manufacturing company. The paper first presents the lean concept tools. The empirical section discusses how a case company, operating as a contract manufacturer in the food industry, has applied the lean production concept and tools. In the case study, three analysis tools are examined and the structures of demand chains of different customers are presented. The delivery times will decrease and more flexibility will be needed from the contract manufacturer. The case study shows that much movement is possible toward the lean supply chain and partnership-based cooperation. By implementing the lean concept, food companies can increase customer value through cost reduction or through provision of additional value-enhanced services.
I. Idrıssi; A. Mesfioui; I. Aftais; B. Benazzouz
Lean is a powerful tool, which can bring significant benefit to manufacturing industries by creating value through reduction of waste. Although the lean concept has become very popular in mass production industries such as the automotive industry, more recently the concept has been adopted in different batch processing industries and service sectors. The application of lean tools into the food processing industry has not received the same level of attention compared...
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ENGLISH ABSTRACT: Opportunities to improve production processes and access to markets through the implementation of lean manufacturing in biomedical manufacturing are presented. The importance of a unified definition of manufacturing, to which biomedical manufacturing is party, is emphasized, and the theory of “lean”, summarized as “purpose, process, people”, is elaborated. The requirements for the creation of value through the creation of flow and the elimination of wastes are highlighted in the context of biomedical manufacturing. Finally, case studies are presented to illustrate the approaches to “purpose, process, people”.
AFRIKAANSE OPSOMMING: Geleenthede vir die verbetering van produksieprosesse en marktoegang via die implementering van skraalvervaardiging in die biomediese vervaardigingsbedryf word voorgehou. Aandag word geskenk aan die betekenis van terme soos “skraal, doel, proses, menes” in die konteks van biomediese vervaardiging. Waardeskepping, vloei en vermorsing word onder die loep geneem. Gevallestudies word ter illustrasie van begrippe aangebied.
Bjørnsen, Egil; Hansen, Louise Ejgod; Vatne, Ingrid
Aarhus 2017 (Aarhus som europæisk kulturhovedstad). Vi undersøger, hvor-dan de positionerer sig i feltet mellem den brede deltagelsesdiskurs og den snævre publikumsudviklingsdiskurs ved at se på tre forskellige dimensioner: produkt- vs. modtagerorientering, holdnings- vs. handlingsændring og empowerment...
MARCELO RUDOLFO CALVETE GASPAR
Full Text Available Lean and Green manufacturing processes aim at achieving lower material and labour costs, while reducing impacts on the environment, and promoting sustainability as a whole. This paper reports on a pilot experiment with higher education and engineering students, exploring the full potential of a collaborative approach on courses integrating the Portuguese Polytechnic of Castelo Branco engineering studies curricula, while simultaneously improving their proficiency in English. Content and Language Integrated Learning (CLIL has become a key area of curricular innovation since it is known for improving both language and content teacher and student motivation. In this context, instructional design for CLIL entailed tandem work of content (engineering and language (English teacher to design learning sequences and strategies. This allowed students to improve not only their language skills in English but also their knowledge in the specific engineering domain content on green and lean manufacturing processes.
Srinivasa Rao, P.; Niraj, Malay
Lean manufacturing is a business strategy developed in Japan. In the present scenario, the global market is developing new techniques for getting more and more production rate with a good quality under low cost. In this context, human factors have to be given importance to their working conditions. The study demonstrates the adoption of ergonomic conditions in lean manufacturing for the improvement of organizational performance of the industry. The aim of ergonomics is to adapt the new techniques to their work in efficient and safe ways in order to optimize the human health conditions and increasing the production rate. By conducting survey on various disciplines and showed how the production rate and human ergonomic conditions is affected.
Full Text Available Lean Manufacturing merupakan pendekatan untuk mengefisienkan system dengan mereduksi pemborosan. Pendekatan ini dilakukan dengan memahami gambaran umum perusahaan melalui aliran informasi dan material di lantai produksi dengan membuat value stream mapping. Aktivitas ini dikelompokkan dalam value added, non value added, dan necessary non value added. Penelitian ini menghasilkan value stream mapping (VSM perusahaan yang meliputi aliran material dan informasi. Dari VSM diketahui peta aktivitas-aktivitas pemborosan di lantai pabrik. Penelitian ini berhasil merinci besar value-adding activity rata-rata sebesar 50.30%, non value-adding activity sebesar 21.83% dan necessary non value-adding activity sebesar 26.36%. Dari PMEA diketahui nilai RPN terbesar pada aktivitas yang berhubungan dengan jig. Untuk mereduksi pemborosan perlu dilakukan management jig yang lebih baik. Kata kunci: fishbone diagram, FMEA, lean manufacturing, value stream mapping. Lean Manufacturing is an approach to make system more efficient by reducing waste. This approach is done by understanding the general outlook of company using value stream mapping of information and material flow in production line. These activities are classified by value added activities, non-value added activities, and necessary value added activities. This research delivers value stream mapping (VSM of company including material and information flow. VSM shows the map of wasting activities in production line. The result of this research is details of activities, that value-adding activity in average 50.30%, non value-adding activity in average 21.83%, and necessary non value-adding activity in average 26.36 %. FMEA shows that the biggest value of RPN is activity that related to jig. Better jig management need to do to reduce waste. Keywords : fishbone diagram, FMEA, lean manufacturing, value stream mapping
Castro, Helio; Putnik, Goran D.; Shah, Vaibhav
Purpose: The aim of this paper is to analyze international and national research and development (R&D) programs and roadmaps for the manufacturing sector, presenting how agile and lean manufacturing models are addressed in these programs. Design/methodology/approach: In this review, several manufacturing research and development programs and…
Khusaini, N. S.; Ismail, A.; Rashid, A. A.
This paper presents a preliminary study on the prominent barriers to lean manufacturing implementation in Malaysian Food and Beverages Industry. A survey was carried out to determine the most prominent barriers of lean manufacturing implementation that are currently being faced in this industry. The amount of barriers identified for this study is twenty seven. Out of 1309 available organizations, a total of 300 organizations have been randomly selected as respondents, and 53 organizations responded. From the variable map, the analysis shows that, the negative perception towards lean manufacturing top the list as the most agreeable barrier, while the technical barriers came after it. It can also be seen from the variable map that averagely, lack of vision and direction is the barrier that is being faced. Finally, this is perhaps the first attempt in investigating the prominent barriers to Lean Manufacturing implementation in Malaysian food and beverages industry using Rasch Model.
Maneechote, T.; Luangpaiboon, P.
A manufacturing process of erbium doped fibre amplifiers is complicated. It needs to meet the customers' requirements under a present economic status that products need to be shipped to customers as soon as possible after purchasing orders. This research aims to study and improve processes and production lines of erbium doped fibre amplifiers using lean manufacturing systems via an application of computer simulation. Three scenarios of lean tooled box systems are selected via the expert system. Firstly, the production schedule based on shipment date is combined with a first in first out control system. The second scenario focuses on a designed flow process plant layout. Finally, the previous flow process plant layout combines with production schedule based on shipment date including the first in first out control systems. The computer simulation with the limited data via an expected value is used to observe the performance of all scenarios. The most preferable resulted lean tooled box systems from a computer simulation are selected to implement in the real process of a production of erbium doped fibre amplifiers. A comparison is carried out to determine the actual performance measures via an analysis of variance of the response or the production time per unit achieved in each scenario. The goodness of an adequacy of the linear statistical model via experimental errors or residuals is also performed to check the normality, constant variance and independence of the residuals. The results show that a hybrid scenario of lean manufacturing system with the first in first out control and flow process plant lay out statistically leads to better performance in terms of the mean and variance of production times.
Rebecca M. Nunesca
Full Text Available This study aimed to use and apply lean tools as ways of improving manufacturing systems that lead to reduction of wastes and standardization of cycle time. Model A in Line 1 at sewing section was the focus of the study. The researcher used questionnaires, 5S Audit checklists, and Time Study forms in information-gathering and cycle time-computation. Based on the observation done, the company does not have a standard operation time. Similarly, the researcher observed non-value activities such as unnecessary transportation and manual counting, and there were also product defects due to poor 5S and WIP inventories. After considering lean tools, using process flow and cycle time analysis, the standard time was determined. Likewise, the non-value added activities were reduced, thus productivity was improved. After lean implementation, 100% efficiency was achieved, the rejection rate was reduced to 0.08% and zero WIP inventories in Line 1 became a practice. Lean tools brought significant changes in providing smooth process flow and productive operations, which in turn, give a remarkable contribution in achieving company’s goals, focus on the customers, giving quality products at the right time and at the right place. Therefore, the full implementation of BY Garments would contribute in gaining more profits.
Full Text Available The goal of this study was to develop an innovative and creative hands-on project based on Lean Six Sigma experiments for engineering education at the College of Engineering at the University of Hail. The exercises were designed using junction box assembly to meet the following learning outcomes: 1-to provide students with solid experience on waste elimination and variation reduction and 2-to engage students in exercises related to assembly line mass production and motion study. To achieve these objectives, students were introduced to the principles of Lean manufacturing and Six Sigma through various pedagogical activities such as classroom instruction, laboratory experiments, hands-on exercises, and interactive group work. In addition, Minitab 17 statistical package and Quality Companion 3 software were used to facilitate The Lean Six Sigma exercises. The software application and hands-on manufacturing assembly were found to be extremely valuable in giving students the chance to identify which variables to control in order to minimize variation and eliminate waste. This research was funded by a grant from the Deanship of Academic Research at University of Hail for project number E-26-IC, and under the umbrella of Ministry of Education within the framework of the National Initiative on Creativity and Innovation in Saudi Universities at University of Hail.
Full Text Available Nowadays, the pharmaceutical industry has a market tends to be unstable and volatile in meeting customer needs. This is due to the economic crisis that occurred in different parts of the world. The pharmaceutical industry currently uses good manufacturing practices (cGMP to ensure that products are consistently produced and controlled according to the required standards. Pharmaceutical industry slowly started to move from cGMP to lean manufacturing that focused on reducing operating costs while ensuring compliance. The purpose of this paper is to analyze the usage of lean manufacturing instead of the usage of cGMP to eliminate wastes. To conduct this study, literature review and company visit has been done. This analysis was applied by using value stream mapping (VSM and 7-wastes methodology to analyze the problems in the OBH (Black Cough Medicine production line one of the pharmaceutical industry in Bandung, Indonesia. For the improvement, the lean manufacturing approach has been carried out and the future VSM has been developed. Finding reveals that the application of lean manufacturing in the cGMP environment helps the company to eliminate wastes in reducing lead time and cycle time in the manufacturing process. Keywords: pharmaceutical industry, cGMP, lean manufacturing, value stream mapping, 7-wastes.
Vinicius Mitsuo Kojima Campos
Full Text Available The competitive scenario requires organizational strategies increasingly elaborated, creating the need of companies to structure their management models in order to absorb these conflicts generated by competition. The manufacturing area is financially affecting deeply the company's results, thus process improvement comes as the organization's survival guideline, and the rationalization of waste without the need for high investments, shown a great competitive alternative. The application of Kaizen event seeks to measure the benefits generated by the implementation of the philosophy of lean manufacturing, working setup aspects of machinery, the manufacturing process flow, reduced delivery lead-time and inventory process. The Kaizen Blitz was applied in a production cell of stamping and spirt processes. The obtained major improvements have been the reduction of machine setup time, reducing lead-time of item processing, the material flow within the production cell, and creating conditions for a more flexible management of the production schedule.
Full Text Available Dalam industri manufaktur, produktivitas merupakan kemampuan perusahaan untuk mengoptimalkan output dari input yang digunakan. Output yang dihasilkan harus dapat memenuhi demand konsumen. PT Smart Tbk Surabaya merupakan salah satu industri manufaktur yang bergerak dalam produksi pengolah minyak kelapa sawit. Dalam proses produksinya terjadi ketidakseimbangan output produksi dengan demand konsumen yang harus dipenuhi. Hal tersebut terjadi karena adanya waste selama proses filling. Permasalahan ini diselesaikan dengan pendekatan Lean Manufacturing dengan memberikan usulan improvement pada proses filling dengan menggunakan metode Line Balancing. Value stream mapping digunakan untuk mengidentifikasi waste yang terjadi selama proses filling berlangsung. Tools yang digunakan dalam lean manufacturing dan line balancing ini digunakan untuk mereduksi cycle time. Berdasarkan hasil analisis didapatkan empat usulan improvement yaitu perbaikan alur proses filling, penggabungan operasi kerja plugging dan capping, continuous flow dengan line balancing dan redesain layout. Usulan improvement tersebut dapat menekan tingkat defect, mengurangi total operation time menjadi 188,55 detik/batch, meningkatkan efisiensi lini menjadi 79,83% dan menurunkan delay time menjadi 23%. Abstract Productivity is the company’s ability to optimize output from all input that they use to production. The output they produce must fulfill the customer demand. PT Smart Tbk Surabaya is one of the private manufacturing industries which are existed in the processing of palm oil. There are unbalance condition during processing the product. The output of the production is different from the customer demand. It happened because there are some wastes during the filling process. This research is focus on solving the problem by using Lean Manufacturing and creating the improvement in filling proces by using line balancing method. The purpose of value stream mapping is to identify waste
Jadhav, J. R.; Mantha, S. S.; Rane, S. B.
The demands for automobiles increased drastically in last two and half decades in India. Many global automobile manufacturers and Tier-1 suppliers have already set up research, development and manufacturing facilities in India. The Indian automotive component industry started implementing Lean practices to fulfill the demand of these customers. United Nations Industrial Development Organization (UNIDO) has taken proactive approach in association with Automotive Component Manufacturers Association of India (ACMA) and the Government of India to assist Indian SMEs in various clusters since 1999 to make them globally competitive. The primary objectives of this research are to study the UNIDO-ACMA Model as well as ISM Model of Lean implementation and validate the ISM Model by comparing with UNIDO-ACMA Model. It also aims at presenting a roadmap for Lean implementation in Indian automotive component industry. This paper is based on secondary data which include the research articles, web articles, doctoral thesis, survey reports and books on automotive industry in the field of Lean, JIT and ISM. ISM Model for Lean practice bundles was developed by authors in consultation with Lean practitioners. The UNIDO-ACMA Model has six stages whereas ISM Model has eight phases for Lean implementation. The ISM-based Lean implementation model is validated through high degree of similarity with UNIDO-ACMA Model. The major contribution of this paper is the proposed ISM Model for sustainable Lean implementation. The ISM-based Lean implementation framework presents greater insight of implementation process at more microlevel as compared to UNIDO-ACMA Model.
Full Text Available This paper presents a new metric for describing the sustainability improvements achieved, relative to the company’s initial situation, after implementing a lean and green manufacturing system. The final value of this metric is identified as the Overall Environmental Equipment Effectiveness (OEEE, which is used to analyze the evolution between two identified states of the Overall Equipment Effectiveness (OEE and the sustainability together, and references, globally and individually, the production steps. The OEE is a known measure of equipment utilization, which includes the availability, quality and performance of each production step, In addition to these factors, the OEEE incorporates the concept of sustainability based on the calculated environmental impact of the complete product life cycle. Action research based on the different manufacturing processes of a tube fabrication company is conducted to assess the potential impact of this new indicator. The case study demonstrates the compatibility between green and lean manufacturing, using a common metric. The OEEE allows sustainability to be integrated into business decisions, and compares the environmental impact of two states, by identifying the improvements undertaken within the company’s processes.
Maldonado-Macías, Aidé; Cortes-Robles, Guillermo
This book presents some definitions and concepts applied in Latin America on lean manufacturing (LM), the LM tools most widely used and human and cultural aspects that most matter in this field. The book contains a total of 14 tools used and reported by authors from different countries in Latin America, with definition, timeline with related research, benefits that have been reported in literature, and case studies implemented in Latin American companies. Finally, the book presents a list of softwares available to facilitate the tools' implementation, monitoring and improvement.
Rivera Cadavid, Leonardo
En los últimos 20 años se han discutido diferentes técnicas que hacen parte de Lean Manufacturing en la literatura gerencial, en presentaciones y conferencias y en ofertas de consultoría. En muchos casos esta presentación de técnicas se ha hecho sin proponer un modelo de implementación que permita la evolución de la empresa en un camino de mejoramiento, y que subraye qué técnicas y principios deberían implementarse antes que otras. En el presente artículo se presenta una estructura de prerreq...
Rui Borges Lopes
Full Text Available Recent years have shown an increasing use of lean manufacturing (LM principles and tools in several industrial sectors. Already a well-established management philosophy, it has shown numerous successful applications even outside production environments. This work presents the application of some LM tools, and the corresponding shift in philosophy, in two Portuguese companies of the food and beverage industries. Main implementation issues are presented and discussed; followed by the results obtained from the application of LM tools in the production system of these companies. Significant gains are obtained in both companies and, more importantly, it instills a continuous improvement culture and increases production flexibility while reducing lead times.
De Sanctis Clemente, Yoel
Con la rápida expansión de la industria del videojuego en los últimos años y la proliferación de equipos de desarrollo independientes, se hace patente la necesidad de aplicación de nuevas técnicas de desarrollo de software y producción de experiencias audiovisuales interactivas para mejorar la productividad y rentabilidad de los proyectos. Una de estas metodologías, Lean Manufacturing, ya está siendo aplicada en procesos de fabricación en masa en industrias como la del automóvil. Muchos de su...
Cildoz Esquíroz, Guillermo
La compañía Trelleborg se puso como objetivo en el año 2013 implantar progresivamente en cada una de sus plantas la filosofía lean manufacturing. En concreto se propuso implantar la herramienta 5s en todas y cada una de las secciones de todas las plantas y completar un plan de mantenimiento TPM en una de sus líneas cada año. El objetivo de este proyecto fin de carrera es la elaboración y el desarrollo de un plan de acciones que permita implantar las diferentes herramientas “lea...
Full Text Available Nowadays organizations compete between themselves in various categories such as faster delivery, price tags, state of art - technology and higher quality dimensio ns. A Conceptual framework with lean manufacturing and hum an factors interventions for improving business performance in terms of improved quality, reduced cost and faster de livery is presented and example s from literature are given to illustrate the desir ed situation in which ergonomics is considered as an integrated part of performance strategy . A case from an industry engaged in manufacturing shafts using lean manufacturing practices with successful ergonomic or human factors interventions is also inves tigated.
Malek, A. K.; Muhammad, H. I.; Rosmaini, A.; Alaa, A. S.; Falah, A. M.
Development and improvement process are essential to the companies and factories of various kinds and this necessity is related aspects of cost, time and risk that can be avoided, these aspects are available at the nuclear power stations essential demands cannot be ignored. The lean management technique is one of the recent trends in the management system. Where the lean management is stated as the system increases the customer value and reduces the wastage process in an industry or in a power plants. Therefore, there is an urgent necessity to ensure the development and improvement in nuclear power plants in the pre-established in process of being established and stage of the management and production. All of these stages according to the study are closely related to the necessity operationalize and apply lean manufacturing practices that these applications are ineffective and clear contribution to reduce costs and control of production processes and the process of reducing future risks that could be exposed to the station.
Full Text Available Recently, Bangladesh readymade garments sector has started the trend of implementing ‘lean manufacturing’. To remain competitive in the global market the most important task for garments industry is to reduce the lead time which is also important for long-term stable development. A headlong rush to reduce lead time by becoming lean has created urgency for researchers and practitioners to apply new tools and techniques for dictating wastages. This research addresses the application of value stream mapping in garments industry to implement lean manufacturing. Value stream mapping is different than conventional recording approaches as it helps in the visualization of Material Flow, Information Flow, cycle times and utilization of resources. With the assurance of effective integration and communication, lean systems can be achieved with better efficiency. This research will stand as a benchmark to implement lean for other garment industries in Bangladesh.
Sandholm, Niels; Nielsen, Ulla Søbjerg; Nielsen, Iben Husted
Forhold mellem profession og bureaukrati undersøges med afsæt i to cases, sygeplejersker på hospital og sygehussocialrådgivere. Det empiriske materiale er fokusgruppeinterviews med to grupper af sygeplejersker og to grupper af socialrådgivere. Perspektivet er mikrosociologisk og der trækkes på an....... Et markant fund er, at mens socialrådgiverne fremstår som overvejende loyale overfor klienter, så udtrykker sygeplejerskerne en højere grad af loyalitet med organisatoriske mål og logikker....
Teixeira, Hipólito Francisco
Esta pesquisa teve por alvo o campo de estudo denominado Lean Accounting (LA) aplicado as empresas que adotam os procedimentos de Produção Enxuta (PE). As empresas neste ambiente competitivo e muito imprevisivel têm procuradoadotar decisões e procedimentos voltadosa valorizar sua própria continuidade e diferencial para se expor perante ao mercado. Neste sentido novas tecnologias de produção e controles contábeis são necessários. Lean Accounting (LA) ou Contabilidade Lean ou “enxuta” pode s...
Full Text Available The increaseing productivity is one of the competitive strategies that can be applied in a company in order to survive in an intense competitive presure. PT. XYZ is a textile industry manufacturing golf gloves and caddy bag. Every day, the company has a production target of 600 pieces per line. However, the desired target is not achieved that it will affect the delay in delivery of products to customers. In this research, a case study on implementing value stream mapping and Kaizen as the lean manufacturing concept is reported. The purpose of this study is to map the current production line, analyse and design the future value stream mapping by eliminating waste occured. It is obtained a lead time reduction as much as 440.4 seconds through eliminating 17 non-value added activities. Then, the output can be increased up to 21% which is equal to 502 pieces.
Full Text Available Lean Manufacturing is a popular tool to be implemented in printing industry fields for the purpose of achieving the successful production goals and it is a well-organized method used to eliminate the waste or non-value added activities. Lean Manufacturing consists of several tools like 5S, TPM, Kanban, Kaizen and others. In this paper, the researcher is focus on TPM (Total Productive Maintenance. TPM is a concept used for maintaining plants and equipment with the involvement of all employees in the company in order to increase the overall equipment effectiveness (OEE. In this paper, the researcher will identify the problem faced in company’s production line and then implement lean tools in order to improve the productivity. Afterward, the researcher will carry out time study on company’s production line. The purpose of time study is to getting the result for OEE and the time taken for producing one piece of product. The researcher is then designed and suggested one-piece flow system to the management with showing the result on simulation that getting improvement in productivity. The result was simulated by using Flexsim and shows that 7.59 seconds was saved in producing one piece of calendar. At the end, the result shows that OEE increase from 34.3% to 60% and the company total save around 6 hours per month by implement one-piece flow. At last, by verifying the distribution of collected data, the researcher will perform Anderson Darling Normality test to ensure the distribution of data are normal.
Siregar, I.; Nasution, A. A.; Andayani, U.; Anizar; Syahputri, K.
This object research is one of manufacturing companies that produce oil palm machinery parts. In the production process there is delay in the completion of the Main shaft order. Delays in the completion of the order indicate the low productivity of the company in terms of resource utilization. This study aimed to obtain a draft improvement of production processes that can improve productivity by identifying and eliminating activities that do not add value (non-value added activity). One approach that can be used to reduce and eliminate non-value added activity is Lean Manufacturing. This study focuses on the identification of non-value added activity with value stream mapping analysis tools, while the elimination of non-value added activity is done with tools 5 whys and implementation of pull demand system. Based on the research known that non-value added activity on the production process of the main shaft is 9,509.51 minutes of total lead time 10,804.59 minutes. This shows the level of efficiency (Process Cycle Efficiency) in the production process of the main shaft is still very low by 11.89%. Estimation results of improvement showed a decrease in total lead time became 4,355.08 minutes and greater process cycle efficiency that is equal to 29.73%, which indicates that the process was nearing the concept of lean production.
Leoni Pentiado Godoy
Full Text Available The main objective of this article is to present the impact that the Lean manufacturing tool can have in a company that does not have management methodology for the Toyota Production System. This work was carried out in an industry that outsources services for the export of the medium-sized leather footwear producers sector located in the industrial pole of RS, Brazil. In the data collection, questions were raised with the managers and collaborators, as well as the researcher’s empirical view on the decisions that were being taken in the productive processes for a period of four months. These data were analyzed using Excel spreadsheets. In the results , the importance of the application of the Lean Manufacturing tools was highlighted , and some suggestions were given to the managers, mainly in relation to the idle capacity of production in several sectors, representing how much more the company could be producing to reach its maximum capacity. The mapping applied identified the adaptation of new machines for better production results, as well as intensifying the mapping of the critical paths that aggregate and do not add value in the productive operating environment.
Colin J. Conway
Full Text Available The impetus towards efficiency in the AECO (Architecture, Engineering, Construction & Operations sector is driving the implementation of Lean practices. BIM technologies and BIM processes provide methods by which this can be achieved. Major clients of building services contractors have begun to mandate the use of BIM and some are using BIM preparedness/experience as pre-tender qualification criteria. In this case study, an initial review has been conducted of the achievements of a major Irish M&E contractor in implementing BIM. The firm purpose-built a facility for the off-site manufacture of building services components. The operations of the plant are efficient and quality assured through the use of an appropriately skilled workforce at all stages of manufacture, and tracking software that has developed as the knowledge of the contractor grew. Standardised processes have been developed which have resulted in greater efficiencies and lower costs for the contractor as a result of fewer requirements for onsite modifications (such as those caused by clashes, less waste, and greater flexibility. Despite some initial objections, the employees of the company are now more satisfied with their working conditions and are, as a result, more productive. Through investment in BIM-based, Lean processes, the contractor can now better compete when tendering for large-scale projects in Ireland and worldwide, including the rapidly-increasing number where BIM experience and preparedness is mandated.
Allen, M; Wigglesworth, M J
Historically, sample management successfully focused on providing compound quality and tracking distribution within a diverse geographic. However, if a competitive advantage is to be delivered in a changing environment of outsourcing, efficiency and customer service must now improve or face reconstruction. The authors have used discrete event simulation to model the compound process from chemistry to assay and applied lean manufacturing techniques to analyze and improve these processes. In doing so, they identified a value-adding process time of just 11 min within a procedure that took days. Modeling also allowed the analysis of equipment and human resources necessary to complete the expected demand in an acceptable cycle time. Layout and location of sample management and screening departments are key in allowing process integration, creating rapid flow of work, and delivering these efficiencies. Following this analysis and minor process changes, the authors have demonstrated for 2 programs that solid compounds can be converted to assay-ready plates in less than 4 h. In addition, it is now possible to deliver assay data from these compounds within the same working day, allowing chemistry teams more flexibility and more time to execute the next chemistry round. Additional application of lean manufacturing principles has the potential to further decrease cycle times while using fewer resources.
Aguirre Alvarez, Yenny Alejandra
Resumen: La presente tesis consiste en analizar las herramientas Lean Manufacturing para la eliminación de desperdicios en las Pymes con el fin de mejorar su productividad. Del estado del arte se logra evidenciar cómo la teoría Lean Manufacturing se encuentra presente en las estrategias organizacionales como metodología para la solución de problemas, de cara a la eliminación de desperdicios principalmente en el eslabón de producción de la cadena de suministro. Se logra posteriormente, la cara...
Suganthini Rekha, R.; Periyasamy, P.; Nallusamy, S.
In recent manufacturing system the most important parameters in production line are work in process, TAKT time and line balancing. In this article lean tools and techniques were implemented to reduce the cycle time. The aim is to enhance the productivity of the water pump pipe by identifying the bottleneck stations and non value added activities. From the initial time study the bottleneck processes were identified and then necessary expanding processes were also identified for the bottleneck process. Subsequently the improvement actions have been established and implemented using different lean tools like value stream mapping, 5S and line balancing. The current state value stream mapping was developed to describe the existing status and to identify various problem areas. 5S was used to implement the steps to reduce the process cycle time and unnecessary movements of man and material. The improvement activities were implemented with required suggested and the future state value stream mapping was developed. From the results it was concluded that the total cycle time was reduced about 290.41 seconds and the customer demand has been increased about 760 units.
Danilo Felipe Silva de Lima
Full Text Available The development of the Value Stream Mapping (VSM is generally the first step for implementation of Lean Manufacturing (LM. The aim of this paper is to present an application of VSM with simulation in order to analyze the impacts of the LM adoption in the performance of a footwear plant. Therefore, a VSM was designed for the current state and, through the implementation of lean elements, a future state could be designed. Different scenarios were simulated for the future state implementation and the results were compared each other. Transfer, cutting and assembly sections were chosen to be simulated, because it was considered that would be possible to establish a one-piece flow between those processes. After the simulation, the scenario that presented the best results provided a 19% productivity increase over the current state, as well as improvement in all other process variables. The application of simulation as an additional element of VSM has helped to identify the advantages of the joint approach, since it enables to test different alternatives and better define the future state and its implementation strategies.
Olga Maria Formigoni Carvalho Walter
Full Text Available Through a review of the proceedings of the National Meeting of Production Engineering (NMPE over the past 10 years, this article aims to identify the profile of Brazilian research regarding methods that assess the implementation of Lean Manufacturing (LM, proposing a classification for the methods analyzed. We identified 28 articles that specifically address the assessment of the implementation of LM, which accounts for 16 evaluation methods because some methods have been found in more than one article. The results show that the type of research most widely used is the case study. Lean practices more addressed are: Quality Tools, Multifunctional Teams, Quick-Changeover Techniques, Continuous Improvement and Visual Control. The presence of the researcher was found more than half of the studies analyzed. Less than half showed the full data collection instrument. Moreover most of the papers evaluate the LM industry, specifically on the shop floor. This article will be useful both to researchers and to professionals in Production Engineering interested in evaluating the progress of LM implementation, because it shows the profile of all the methods presented in NMIE, which reflects the progress in the Brazilian research on the subject.
Setiyawan, D. T.; Pertiwijaya, H. R.; Effendi, U.
PT. XYZ is a company specialized in the processing of fishery products particularly in frozen fish fillet. The purpose of this research was to identify the type of waste and determine the recommendations of minimizing waste Lean manufacturing approach was used in the identification of waste by describing the Value Stream Mapping (VSM) and selecting tools in the Value Stream Analysis Tools (VALSAT). The results of this research showed that the highest waste that generated was the defect of leak packaging on fillet products with an average of 1.21%. In addition to defect, other insufficiencies were found such as: unnecessary motion, unnecessary overhead, and waiting time. Recommendations for improvements that given include reduction of time at several stages of the process, making production schedules, and conducting regular machine maintenance. VSM analysis shows reduced lead time of 582.04 minutes to 572.01 minutes.
Full Text Available Initiatives toward Lean and Green Manufacturing are given mainly due to organisational response to current market’s economic and environmental pressures. This paper, therefore, aims to present a brief discussion based on a literature review of the potential two-way influence between Lean and Green Manufacturing and its role on the main organisational areas with a closer relationship to such approaches, which were observed to be more extensively discussed in the literature. Naturally lean practises seem more likely to deploy into green outcomes, though the other way around can also occur. There is some blur on the factual integration of both themes, as some authors suggest. Notwhithstanding, they certainly present certain synergy. Thereupon, further research is needed to unveil the real ties, overlaps and gaps between these approaches.
På baggrund af filosoffen Ludwig Wittgensteins (1889-1951) dagbogsoptagelser fra 1930-erne beskriver forfatteren hans tilgang til religionen, der synes at have befundet sig på et knivsæg mellem tro og tvivl......På baggrund af filosoffen Ludwig Wittgensteins (1889-1951) dagbogsoptagelser fra 1930-erne beskriver forfatteren hans tilgang til religionen, der synes at have befundet sig på et knivsæg mellem tro og tvivl...
Cullinane, S.J.; Bosak, J.; Flood, P.C.; Demerouti, E.
Studies examining the relationship between lean manufacturing and employee well-being to date have yielded contradictory findings, whereby positive, negative and contingent effects have all been demonstrated. These inconsistencies are partly attributed to the absence of an appropriate model that
Hargis, L; Botkin, J.
PowerLight Corporation (PowerLight) has completed Phase I of its PV Manufacturing R&D subcontract, ''PowerGuard Lean Manufacturing,'' Subcontract No. NDO-1-30628-04. The overall technical goal of this project was to reduce the cost of PowerGuard manufacturing while simultaneously improving product quality. This will enable PowerLight to scale up production capacity as the market for PowerGuard continues to grow. Through the introduction of world-class lean manufacturing techniques, PowerLight was to cut out waste in the manufacturing process of PowerGuard. The manufacturing process was to be overhauled with an objective of removing as much as possible those steps that do not add value to the product. Quality of finished goods was also to be improved through the use of statistical process control and error-proofing in the manufacturing process. Factory operations were also to be addressed to streamline those factory activities that support the manufacturing process. This report de tails the progress made toward the above listed goals during the first phase of this subcontract.
Full Text Available Every company wishes to provide the best possible service to their customers bydelivering their products on time, for which quality and production lead time are the key factorsthat need continuous improvements by way of adopting the right internal strategy. This researchapplies the concept of lean manufacturing to identity wastes along the value stream to find outnon added value activities. In the initial stage, Big Picture Mapping is used to describe thewhole stream entirely, than Process Activity Mapping is used to find value added, non valueadded and necessary-but-non-value added activities, whilst Quality Filter Mapping is used tofind the defects of the quality of defect type. In the last stage, Total Product Maintenance(TPM is applied to minimize defects by means of Overall Equipment Effectiveness (OEE. TheOEE Sensitivity analysis is applied to the operating time, cycle time and defects to find out themost influential factor for the improvement of OEE. The result of this research has identifiedcycle time as the influential factor that affects the OEE value. The 10% decrease in cycle timewill improve OEE by 10,20%
Full Text Available PT. Nipro Indonesia Jaya (NIJ sebagai salah satu perusahaan manufaktur yang bergerak di bidang Alat Kesehatan tidak terlepas dari masalah yang berkaitan dengan pencapaian output produksi yaitu proses perakitan Intra Venous Catheter (IV Cath. Rata-rata pencapaian output produksi IV Cath adalah sebesar 94% dari target perusahan yaitu 100%. Tidak tercapainya output produksi pada setiap bulan akan menyebabkan pengiriman produk ke customer akan terganggu karena proses produksi menggunakan sistem made to order. Dari informasi yang didapatkan dari dept. produksi, dalam proses perakitan IV Cath saat ini masih sering ditemukan pemborosan atau waste. Dengan metode Lean Manufacturing penulis berharap terjadi peningkatan output produksi produk IV Cath. Pemborosan yang terjadi diidentifikasi dengan seven waste. Kondisi perusahaan digambarkan dengan Big Picture Mapping. Analisa dilakukan dengan Value Stream Analysis Tools (VALSAT untuk kemudian diketahui akar penyebabnya. Dari hasil pengolahan data didapatkan nilai rata-rata tertinggi untuk pemborosan yaitu; transportation (54.8%. waiting (23.0%, motion (18.3% dan inventory (4.0%. Nilai rata-rata dikalikan dengan factor pengali pada VALSAT, sehingga didapatkan VALSAT yang digunakan adalah Process Activity Mapping (110.67. Waktu lead time sebelum perbaikan adalah sebesar 8,992 detik dan setelah perbaikan menjadi 6,902 detik. Output produksi meningkat sebesar 10% dari 292,768 pcs/bulan menjadi 321,333 pcs/bulan.
Siregar, I.; Nasution, A. A.; Andayani, U.; Sari, R. M.; Syahputri, K.; Anizar
This research is based on case study that being on electrical company. One of the products that will be researched is the fan, which when running the production process there is a time that is not value-added, among others, the removal of material which is not efficient in the raw materials and component molding fan. This study aims to reduce waste or non-value added activities and shorten the total lead time by using the tools Value Stream Mapping. Lean manufacturing methods used to analyze and reduce the non-value added activities, namely the value stream mapping analysis tools, process mapping activity with 5W1H, and tools 5 whys. Based on the research note that no value-added activities in the production process of a fan of 647.94 minutes of total lead time of 725.68 minutes. Process cycle efficiency in the production process indicates that the fan is still very low at 11%. While estimates of the repair showed a decrease in total lead time became 340.9 minutes and the process cycle efficiency is greater by 24%, which indicates that the production process has been better.
Full Text Available Foreign multinational companies with a production subsidiary in Brazil are in general recognized as high-level productive companies; however, their productivity potential is mostly not fully achieved. Lean Manufacturing (LM has been proved as a valuable aid to achieve competitiveness in the long run. Regarding the rising importance of successfully implementing LM at multinationals in Brazil and an apparent lack of discussion regarding LM in Brazil this paper aims to propose a comprehensive implementation roadmap, which enables a multinational on a basis of a systematic approach, to achieve an advanced sustainable LM system in a practical manner. The insights of literature and case studies are combined to develop the roadmap. The roadmap was developed so that both companies, those, which have not started yet their journey towards LM, as well as those that have taken already the first steps can use the roadmap. However, the roadmap was built on a broad empirical basis. It should be noticed that it is impossible to consider all factors influencing the LMI at multinationals operating in Brazil in a real world setting. As a result, the roadmap should not be regarded as a ready implementation plan, which has to be strictly followed. Instead, it should be seen as a guideline, which helps a multinational to develop its own, detailed and fitted plan for successfully implementing LM and establishing a learning organization.
Oláh Judit; Szolnok Ádám; Nagy Gyula; Lengyel Péter; Popp József
Several enterprises have tried to introduce the lean approach in order to enhance competitiveness. However, the only successful ones were the companies which understood that lean is not only about methods and tools, but the people using them: employees. The only way an enterprise can become a lean organisation is if all of its members deeply identify with the organisation’s principles, which is then manifested in all decisions and actions of the organisation. The aim of this study is to prese...
Nielsen, Birgitte Lund
Review af resultater fra 10 års publikationer i Teaching and Teacher Education i relation til samarbejde mellem profession og uddannelse i partnerskaber og forsøgsskoleregi viser, at der er bred konsensus om, at det centrale formål er alle aktørers læring gennem bedre praktik i den primære...... konkrete samarbejder mellem profession og uddannelse; FoU, der både undersøger de resultater, der opnås gennem sådanne samarbejder, og de fremmende og hæmmende faktorer for udvikling af selve samarbejdet....
de Bucourt, Maximilian; Busse, Reinhard; Güttler, Felix; Wintzer, Christian; Collettini, Federico; Kloeters, Christian; Hamm, Bernd; Teichgräber, Ulf K
OBJECTIVES: To apply the economic terminology of lean manufacturing and the Toyota Production System to the procurement of vascular stents in interventional radiology. METHODS: The economic- and process-driven terminology of lean manufacturing and the Toyota Production System is first presented, including information and product flow as well as value stream mapping (VSM), and then applied to an interdisciplinary setting of physicians, nurses and technicians from different medical departments to identify wastes in the process of endovascular stent procurement in interventional radiology. RESULTS: Using the so-called seven wastes approach of the Toyota Production System (waste of overproducing, waiting, transport, processing, inventory, motion and waste of defects and spoilage) as well as further waste characteristics (gross waste, process and method waste, and micro waste), wastes in the process of endovascular stent procurement in interventional radiology were identified and eliminated to create an overall smoother process from the procurement as well as from the medical perspective. CONCLUSION: Economic terminology of lean manufacturing and the Toyota Production System, especially VSM, can be used to visualise and better understand processes in the procurement of vascular stents in interventional radiology from an economic point of view.
Haragovics, Máté; Mizsey, Péter
This work investigates the techniques used in evaluating distillation structures from lean manufacturing point of view. Oil and gas industry has already started adopting lean manufacturing principles in different types of processes from information flow to processing technologies. Generally, energy costs are the most important factors in processing hydrocarbons. Introducing flexibility desired by lean principles to the system may conflict energy efficiency of the system. However, this does not mean that the economic optimum is the energetic optimum. Therefore all possible changes due to temporarily stopped or not fully utilised plants have to be investigated, resulting in a large amount of cases that have to be evaluated. For evaluation exergy analysis can be used as it involves all energy types, and evaluation is straightforward. In this paper plain distillation structures are investigated, and the boundaries of the systems are set up according to the status of the site. Four component case studies are presented that show that the very same distillation structure can be more or less efficient depending on the status of the industrial site. It is also shown that exergy analysis used with different boundaries on the same system can show flexibility of the system and reveals potentials. - Highlights: • The article focuses on the flexibility aspect of lean manufacturing. • Exergy analysis of distillation scheme alternatives, energy efficiency. • Different boundaries define different scenarios of the same system is investigated. • The energy efficiency of distillation schemes also depends on their operating mode. • The exergy reserves of a distillation system can be revealed with exergy analysis
Monroe-Wise, Aliza; Reisner, Elizabeth; Sherr, Kenneth; Ojakaa, David; Mbau, Lilian; Kisia, Paul; Muhula, Samuel; Farquhar, Carey
As human immunodeficiency virus (HIV) treatment programs expand in Africa, delivery systems must be strengthened to support patient retention. Clinic characteristics may affect retention, but a relationship between clinic flow and attrition is not established. This project characterized HIV patient experience and flow in an urban Kenyan clinic to understand how these may affect retention. We used Toyota's lean manufacturing principles to guide data collection and analysis. Clinic flow was evaluated using value stream mapping and time and motion techniques. Clinic register data were analyzed. Two focus group discussions were held to characterize HIV patient experience. Results were shared with clinic staff. Wait times in the clinic were highly variable. We identified four main barriers to patient flow: inconsistent patient arrivals, inconsistent staffing, filing system defects, and serving patients out of order. Focus group participants explained how clinic operations affected their ability to engage in care. Clinic staff were eager to discuss the problems identified and identified numerous low-cost potential solutions. Lean manufacturing methodologies can guide efficiency interventions in low-resource healthcare settings. Using lean techniques, we identified bottlenecks to clinic flow and low-cost solutions to improve wait times. Improving flow may result in increased patient satisfaction and retention.
Full Text Available Several enterprises have tried to introduce the lean approach in order to enhance competitiveness. However, the only successful ones were the companies which understood that lean is not only about methods and tools, but the people using them: employees. The only way an enterprise can become a lean organisation is if all of its members deeply identify with the organisation’s principles, which is then manifested in all decisions and actions of the organisation. The aim of this study is to present the practical use of the lean approach in the Nyíregyháza plant of LEGO. Based on the questionnaire results and our observations, we present the current situation of LEGO in accordance with the same points and compare it to an ideal situation. We then make improvement recommendations in all cases when negative changes were observed.
Despite many significant contributions and advances of lean thinking recorded in articles, books, and industrial case studies, its impact upon the maintenance function has not been fully investigated. From a maintenance perspective, excluding TPM, little or no insight into the use of lean thinking concepts in maintenance can be found in the literature, despite prominent contributors advocating greater management and business integration. An objective of the research describe...
Gemma Eka Santoso
Full Text Available Lean production has dramatically lifted the competitiveness of many manufacturing companies and the value they deliver to customers. This project examines the benefit of balancing process and workstation arrangement of dogbone damper in an order that maintains a smooth flow of materials and component through the process. The analysis begins from calculating takt value to establish the required rate of production. From here, any total cycle time exceeding takt time is called a bottleneck process and should become a target of the improvement. Next, arranging people and equipment into cells has great advantage in terms of achieving lean goals. One advantage of cells is the one-piece flow concept, which states that each product moves through the process one unit a time without sudden interruption, at a pace determined by the customer’s need.
Full Text Available This research was aimed at assessing for manufacturing a small and medium enterprise of electronic industry case study in the Northeast of Thailand. Electronic industry produces integrated circuits products (IC. We use lean assessment tools with 14 lean technique and tools. The value of lean assessment are scoring system derived from the malcolm baldrige national quality award, the two-dimensioned scoring system composing of the process; approach, deployment, learning, and integration. There are reveal operations of each of lean techniques and tools, and the performance; the 0 - 4 level needed to be improved in depth and hence would reflect operations requiring sustainable outcomes. This lean assessment is a systematic approach, assessor come to sit, examine operations from a lean perspective and assessed the situation as prior. The purposes of this visit were to introduced to production or factory manager or window person of SMEs who gave assessor a tour of the plant. Assessor also got a chance to explain lean assessment criteria on the shop floor. Assessor selects a value streaming line that produce most goods or main production line to assess. Assessor takes 1 day to assess and discuss the lean assessment. As a result, the lean assessment survey should be adjusted to fit the systems adaptively. Three plants of electronic industries were leanness of 1.06 or 26%. Five plants of garment industry were leanness of 1.13 or 28%. Four plants of shoe industry were leanness of 1.39 or 34%. Shoe industry had high leanness all unless quick changeover and multi skill. The quick changeover and multi skill were high score on garment industry. Electronics industry has not the lead but second in visual management, 5s, operation base layout, quick changeover, multi skill, standard operation procedures, and policy deployment.
Holistic approach to production systems from the perspective of lean manufacturing and viable systems model; Aproximacion holistica a los sistemas de produccion desde la perspectiva Lean Manufacturing y Modelos de Sistemas Viables
Puche Regaliza, J. C.; Costas Gual, J.
The reductionism approach usually adopted by many organizations provokes too often a problem of sustain ability in the market over time in these organizations. To increase this sustain ability, we propose a structural and a behavioral change, in a way that the reductionism is replaced by an holistic approach appropriate to address the dynamic complexity inherent in any organization. With regard to structural change, we propose the use of Organizational Cybernetics and particularly the Viable System Model. With respect to behavior change, we propose the use of Lean Manufacturing paradigm. (Author)
Georgsen, Marianne; Davidsen, Jacob
I denne rapport præsenteres resultater fra følgeforskningen til projektet Læring gennem Bevægelse, som er gennemført på Søndervangskolen i Hammel i perioden august 2009 - maj 2010. Projektet er gennemført i samspil mellem lærere, it-vejleder, elever og skolens ledelse. Projektets overordnede formål...
mindst betydningen af den kulturelle union, som eksisterede mellem de to lande frem til begyndelsen af 1900-tallet. Samtidig med at København i næsten 100 år vedblev at være Norges kulturelle hovedstad, spillede norske kunstnere som Henrik Ibsen, Bjørnstjerne Bjørnson og Edvard Grieg en afgørende rolle...
Arango Uribe, Juliana María
El sector hotelero en la ciudad de Medellín ha tenido un crecimiento significativo en los últimos años, registrando uno de los mejores momentos históricos en ocupación hotelera, motivo por el cual surge el interés por evaluar el sector -- Este proyecto busca evaluar el grado de implementación de Lean Manufacturing en diferentes hoteles ubicados en la ciudad de Medellín, para la investigación se desarrolló un cuestionario, el cual fue aplicado a una muestra de hoteles -- Del cuestionario se o...
Er. Rajesh Kumar MEHTA
Full Text Available At present scenario, Lean Manufacturing has become a world wide phenomenon. It is quite successful in drawing the attention of companies of all sizes. A large number of organizations are following Lean technologies and experiencing vast improvements in quality, production, customer service, and profitability. Lean Manufacturing is a systematic approach to identifying and eliminating waste through continuous improvement. The manufacturing industry in India must also look to leverage its advantages, its large domestic market, good conditions in terms of raw materials and skilled labour, and the quality focus. In India at the state level, there are few companies that are implementing Lean manufacturing techniques. In Dewas city, the industrial town of Madhya Pradesh, some of the automobile companies are vigorously following the Lean manufacturing techniques to eliminate waste and downsize the cost. Hence, all these factors prompted the researchers to analyze and study the implication of Lean Manufacturing Practices in Automobile Industries.
Karlsson, Anna-Malin; Nikolaidou, Zoe
This article reports on research addressing the role of incident reporting at the workplace as a textual representation of lean management techniques. It draws on text and discourse analysis as well as on ethnographic data, including interviews, recorded interaction, and observations, from two projects on workplace literacy in Sweden: a study in…
Kleine en middelgrote bedrijven uit de maakindustrie ervaren toenemende eisen met betrekking tot de kwaliteit van producten en processen. Om in competitie te blijven is voortdurend verbeteren van cruciaal belang, en de Lean Six Sigma benadering biedt veelbelovende mogelijkheden om continu verbeteren
Alblas, A.A.; Wortmann, J.C.
The present study describes the effects of product platform changes on lean production systems. Current research into product platforms focuses mostly on the development stage. However, although the initial development of platforms is an important issue, product platforms often evolve during later
Carter, Patrick M.; Desmond, Jeffery S.; Akanbobnaab, Christopher; Oteng, Rockefeller A.; Rominski, Sarah; Barsan, William G.; Cunningham, Rebecca
Background Although many global health programs focus on providing clinical care or medical education, improving clinical operations can have a significant effect on patient care delivery, especially in developing health systems without high-level operations management. Lean manufacturing techniques have been effective in decreasing emergency department (ED) length of stay, patient waiting times, numbers of patients leaving without being seen, and door-to-balloon times for ST-elevation myocardial infarction in developed health systems; but use of Lean in low to middle income countries with developing emergency medicine systems has not been well characterized. Objectives To describe the application of Lean manufacturing techniques to improve clinical operations at Komfo Anokye Teaching Hospital in Ghana and to identify key lessons learned to aid future global EM initiatives. Methods A three-week Lean improvement program focused on the hospital admissions process at Komfo Anokye Teaching Hospital was completed by a 14-person team in six stages: problem definition, scope of project planning, value stream mapping, root cause analysis, future state planning, and implementation planning. Results The authors identified eight lessons learned during our use of Lean to optimize the operations of an ED in a global health setting: 1) the Lean process aided in building a partnership with Ghanaian colleagues; 2) obtaining and maintaining senior institutional support is necessary and challenging; 3) addressing power differences among the team to obtain feedback from all team members is critical to successful Lean analysis; 4) choosing a manageable initial project is critical to influence long-term Lean use in a new environment; 5) data intensive Lean tools can be adapted and are effective in a less resourced health system; 6) several Lean tools focused on team problem solving techniques worked well in a low resource system without modification; 7) using Lean highlighted that
Carter, Patrick M; Desmond, Jeffery S; Akanbobnaab, Christopher; Oteng, Rockefeller A; Rominski, Sarah D; Barsan, William G; Cunningham, Rebecca M
Although many global health programs focus on providing clinical care or medical education, improving clinical operations can have a significant effect on patient care delivery, especially in developing health systems without high-level operations management. Lean manufacturing techniques have been effective in decreasing emergency department (ED) length of stay, patient waiting times, numbers of patients leaving without being seen, and door-to-balloon times for ST-elevation myocardial infarction in developed health systems, but use of Lean in low to middle income countries with developing emergency medicine (EM) systems has not been well characterized. To describe the application of Lean manufacturing techniques to improve clinical operations at Komfo Anokye Teaching Hospital (KATH) in Ghana and to identify key lessons learned to aid future global EM initiatives. A 3-week Lean improvement program focused on the hospital admissions process at KATH was completed by a 14-person team in six stages: problem definition, scope of project planning, value stream mapping, root cause analysis, future state planning, and implementation planning. The authors identified eight lessons learned during our use of Lean to optimize the operations of an ED in a global health setting: 1) the Lean process aided in building a partnership with Ghanaian colleagues; 2) obtaining and maintaining senior institutional support is necessary and challenging; 3) addressing power differences among the team to obtain feedback from all team members is critical to successful Lean analysis; 4) choosing a manageable initial project is critical to influence long-term Lean use in a new environment; 5) data intensive Lean tools can be adapted and are effective in a less resourced health system; 6) several Lean tools focused on team problem-solving techniques worked well in a low-resource system without modification; 7) using Lean highlighted that important changes do not require an influx of resources; and
Full Text Available Nowadays, manufacturing companies are striving for a better system like lean manufacturing (LM. The primary objective of LM is to identify and eliminate wastes. LM can be applied successfully in all industries providing a full understanding of lean ingredients i.e. concept, principles, and practices. There are a lot of practices which are necessary to be implemented in order to gain full benefits of LM. However, small and medium enterprises (SMEs are lack of knowledge in LM and facing difficulties to adopt all of the LM principles. Therefore, it is necessary to the researchers to come out with a simple guideline for LM implementation. The objective of this paper is to explore the journey of LM implementation including preliminary, in process and post of LM. This research was conducted through multi-case study research. There were four SMEs and two large companies. The gathered information shows that the preliminary stage of LM implementation is similar to each other including large companies. The result shows SMEs still have a potential to success in LM. This finding might give an opportunity to SMEs to prepare the basis for LM implementation effectively. As a result, SMEs able compete in the competitive global marketplace and strive for world class performance through implementation of LM.
Diego Augusto de Jesus Pacheco
Full Text Available O principal objetivo deste estudo foi analisar os pontos de convergência e as divergências entre a Teoria das Restrições, o Lean Manufacturing e o Seis Sigma quando usados de maneira integrada para a melhoria contínua operacional de sistemas produtivos. O eixo principal de discussão desse estudo foi buscar identificar na literatura características de exclusão e similaridades entre as três abordagens quando aplicadas de maneira integrada em sistemas produtivos. Para conduzir essa pesquisa, fez-se uma ampla pesquisa bibliográfica, entre 1995 e 2011, nas principais bases de dados nacionais e internacionais, em busca do estado da arte sobre o tema. Os resultados desse estudo sugerem que Teoria das Restrições, Lean Manufacturing e Seis Sigma possuem diversos elementos complementares que se sobrepõem aos pontos divergentes e que há um vasto campo de pesquisa a ser explorado sobre o tema. Como resultado, o presente estudo apresenta a análise crítica comparativa de 28 critérios relevantes à compreensão das três abordagens assim como uma agenda de pesquisa sobre o tema identificada a partir das lacunas encontradas.
Travail d’organisation du lean manufacturing et santé : à la source des risques Organizational work of lean manufacturing and health: the source of risks Trabajo de organización « lean manufacturing» y salud: el origen de riesgos
Full Text Available L’objectif de cet article est de mettre au débat une réflexion sur les liens entre la santé au travail et la manière dont est menée la constitution de l’organisation de la production « lean manufacturing ». À travers une revue de la littérature, nous avons pu relever, par le passé, un certain nombre de dispositifs organisationnels du lean ayant des effets paradoxaux sur la santé. Dans cet ouvrage, nous cherchons, de manière théorique, des pistes pour agir sur le travail d’organisation qui conduit à ces effets paradoxaux lors de la mise en œuvre des dispositifs. Au cours de cette recherche, nous constatons que le lean dispose de cadres, d’un prescrit, à l’acte d’organiser. Ces cadres sont, eux-mêmes, porteurs d’effets paradoxaux quant au travail et à la santé.The aim of this paper is to open the debate about the relationship between occupational health and how the organization is built in lean manufacturing. Through a literature review, we have identified a number of organizational devices in lean system with paradoxical effects on health. In this work, we seek, in theory, ways to influence the organizing work that leads to the paradoxical effects in the implementation of the devices. In this research, we find that lean and system production rationalization have frameworks to the organizing act. Frameworks which themselves are carriers of paradoxical effects on work and health.El presente artículo tiene como objetivo abrir el debate con vistas a reflexionar sobre la relación que existe entre la salud en el trabajo y la manera en que es llevada a cabo la organización de la producción « lean manufacturing ». La revisión de la literatura permitió identificar un cierto número de herramientas y dispositivos organizacionales que tienen un efecto paradójico en la salud. Este trabajo busca, de manera teórica, encontrar pistas para actuar sobre el trabajo de organización que conduce a tales efectos en el
Engelund, Eva Høy
produktkvaliteten vha produktionsledelse af måltidsproduktion diskuteres i forhold til anvendeligheden af produktionsprincippet ”Lean” i storkøkkener. Implementeringen af Lean følges i et case studie i Centralkøkkenet på Glostrup Hospital og de lovende effekter heraf præsenteres. På baggrund af resultaterne i disse...... cases blev det konkluderet, at både måltidselementer og Lean kan anvendes i offentlig måltidsproduktion og føre til forbedring af produktkvaliteten. Afhandlingen præsenterer således to nye inputs til designet af offentlige måltidssystemer; en ny form for ingredienser og en ramme for forbedring af...
Gustavo Antiqueira Goes
Full Text Available This paper aims to conduct a Systematic Literature Review (SLR to identify how to configure the publications that relate WCM and Lean Production issues. Therefore, a search on the Brazilian metasearch portal called CAPES Periodicals was conducted focusing on articles of the last five years. They were identified after screening and filtering a total of 42 articles, which were analyzed. The construction of the network analysis has identified that the issues are still in an initial phase of association, with the characteristic part of decentralizes networks, with some points of greatest association. It was also identified that the theme Lean Production has greater representation between the two topics due its higher use by authors.
Guilherme Luz Tortorella
Full Text Available The Lean Production (LP is an approach that encompasses a variety of management practices to reduce losses and improve operational efficiency. Due to this fact, the ability to innovate, change and learn continuously presents itself as a key element in the implementation of the LP. Several contextual variables were mentioned in the literature as potential impediments to implementing lean. However, little is known about the influence of these variables on the dimensions of Organizational Learning (OL. This study aims to examine the relationship between six contextual variables and the frequency of occurrence of problems in companies that are implementing the LP. Furthermore, the identification of relevant relationships between dimensions of OL and contextual variables contribute to the identification of the contexts in which problems can be expected to occur. The sample contains thirteen companies implementing the LP. The results indicate that the same contextual variables, which are deemed as influential to implement LP, have a different influence on the ability of organizational learning.
Lively, Brooks; Kumar, Sandeep; Tian, Liu; Li, Bin; Zhong, Wei-Hong
In this study we report the advantages of a 2-step method that incorporates an additional process pre-conditioning step for rapid and precise blending of the constituents prior to the commonly used melt compounding method for preparing polycarbonate/oxidized carbon nanofiber composites. This additional step (equivalent to a manufacturing cell) involves the formation of a highly concentrated solid nano-nectar of polycarbonate/carbon nanofiber composite using a solution mixing process followed by melt mixing with pure polycarbonate. This combined method yields excellent dispersion and improved mechanical and thermal properties as compared to the 1-step melt mixing method. The test results indicated that inclusion of carbon nanofibers into composites via the 2-step method resulted in dramatically reduced ( 48% lower) coefficient of thermal expansion compared to that of pure polycarbonate and 30% lower than that from the 1-step processing, at the same loading of 1.0 wt%. Improvements were also found in dynamic mechanical analysis and flexural mechanical properties. The 2-step approach is more precise and leads to better dispersion, higher quality, consistency, and improved performance in critical application areas. It is also consistent with Lean Manufacturing principles in which manufacturing cells are linked together using less of the key resources and creates a smoother production flow. Therefore, this 2-step process can be more attractive for industry.
Del Bosque Treviño, César A.
El creciente índice de competitividad ha obligado a las empresas mexicanas a luchar por mantenerse a flote. Se sabe que la carencia de inversión en innovación en el país es un problema que sigue encadenando a México en el tercer mundo. Es por esto que actualmente la innovación de procesos, específicamente la implementación de Lean Manufacturing, es lo mínimo indispensable para subsistir en países de primer mundo y es una ventaja competitiva en México. En la presente investigación se llevó...
Sørensen, Torben; Conrad, Finn
Når mange forskelligartede programmer benyttes til beregninger og anden databehandling på samme modeller er det nødvendig at udveksle modellerne mellem disse forskellige programmer. Biler og skibe bliver f.eks. typisk designet i 3D CAD systemer, mens CAD modellerne herefter anvendes i andre...... dedikerede IT-systemer i forbindelse montageplanlægningen, svejseplanlægningen, robotprogrammeringen mm. der således her et behov for at udveksle CAD modellen mellem de forskellige programmer. Udveksling af information mellem forskellige programmer og systemer kræver såvel en fælles specifikation af det...
Elisabeth Hager, MD, MMM, CPE, is teaming up with scientists and industrialists to teach physicians how to apply principles of lean, total-quality manufacturing to their practices. She believes innovation and efficiencies can help doctors resurrect their profession's image and their control over it--and perhaps even reinvent American health care.
Juan Baldemar Garza Villegas
Full Text Available Presents the MICMAC and MACTOR prospective analysis study in an operational area which looks for world-class management with reference to the concepts of lean manufacturing. The results of a qualitative analysis and his conclusions are presented.
Marodin, G. A.
Full Text Available Despite the fact that lean production (LP is widely used by companies from a broad number of countries and sectors, to achieve a mature LP project implementation is still considered hard to accomplish and sustain. The fact that LP is highly context dependent is one of the major difficulties that hinder its implementation. The extant knowledge about LP implementation from emerging markets is still murky and substantially lower than from developed countries This paper emphasizes LP in Brazil, one of the emerging economies where there is relatively little knowledge about how companies are implementing LP. The existing literature of LP in this country is rare and focused mainly on case studies with a few selected companies. For that, a survey with 49 firms of the automotive supply chain of Brazil was carried out and data collected was analyzed by means of multivariate techniques.
Rapport over Den Internationale Matematikerkongres 2006: Hvad rangerer højst i 2006? Stokastik er kommet hjem. Forholdet mellem ren og anvendt matematik. Historie og didatik. Dansk synlighed - storhed eller begyndende senilitet? Udgivelsesdato: December 2006...
Ford, Andria L; Williams, Jennifer A; Spencer, Mary; McCammon, Craig; Khoury, Naim; Sampson, Tomoko R; Panagos, Peter; Lee, Jin-Moo
Earlier tissue-type plasminogen activator (tPA) treatment for acute ischemic stroke increases efficacy, prompting national efforts to reduce door-to-needle times. We used lean process improvement methodology to develop a streamlined intravenous tPA protocol. In early 2011, a multidisciplinary team analyzed the steps required to treat patients with acute ischemic stroke with intravenous tPA using value stream analysis (VSA). We directly compared the tPA-treated patients in the "pre-VSA" epoch with the "post-VSA" epoch with regard to baseline characteristics, protocol metrics, and clinical outcomes. The VSA revealed several tPA protocol inefficiencies: routing of patients to room, then to CT, then back to the room; serial processing of workflow; and delays in waiting for laboratory results. On March 1, 2011, a new protocol incorporated changes to minimize delays: routing patients directly to head CT before the patient room, using parallel process workflow, and implementing point-of-care laboratories. In the pre and post-VSA epochs, 132 and 87 patients were treated with intravenous tPA, respectively. Compared with pre-VSA, door-to-needle times and percent of patients treated ≤60 minutes from hospital arrival were improved in the post-VSA epoch: 60 minutes versus 39 minutes (PLean process improvement methodology can expedite time-dependent stroke care without compromising safety.
Alvaro Luiz Neuenfeldt Júnior
Full Text Available Nos últimos anos, é notória a evolução das empresas brasileiras no que tange a busca por otimizar os seus resultados industriais. Estudos do Lean Institute Brasil (2012 indicam que as indústrias do Brasil são, em média, as que necessitam o maior número de horas extras para o cumprimento das operações de manufatura, fato diretamente vinculado à elevada quantidade de estoques entre processos, desperdícios na movimentação e armazenagem de materiais. Logo, o artigo objetiva desenvolver uma metodologia que viabilize o estudo da maneira na qual funciona a cadeia de suprimentos interna de empresas fabricantes de ônibus do Brasil, em específico para os seus componentes comprados, com base no método denominado Making Materials Flow, para a correção das situações elencadas, havendo, ao final, uma redução em 40% do total de itens em falta para a linha de montagem e colaborando para o aumento de 37% na produção por dia.
REDUKSI PEMBOROSAN UNTUK PERBAIKAN VALUE STREAM PRODUKSI “MI LETHEK” MENGGUNAKAN PENDEKATAN LEAN MANUFACTURING (Waste Reduction to Improve Value Stream of “Mi Lethek” Production Using Lean Manufacturing Approach
of raw materials. These recommendations could increase PCE score to 15,68 %. Keywords: Waste, value stream, “Mi Lethek”, lean manufacturing ABSTRAK Industri “Mi Lethek” merupakan industri yang menghasilkan produk berupa mi kering berbahan baku tepung tapioka. Pada proses pengolahan mi di industri “Mi Lethek”, terdapat berbagai pemborosan ( yang dapat merugikan industri. Diantara pemborosan yang terjadi berupa persediaan bahan baku yang belum diperlukan dan transportasi berlebih. Untuk mereduksi pemborosan tersebut diperlukan suatu perbaikan pada menggunakan pendekatan . Pendekatan aktivitas yang ada pada industri “Mi Lethek”. Aktivitas-aktivitas tersebut kemudian digolongkan menjadi dua jenis aktivitas, yaitu aktivitas yang memberikan nilai tambah dan aktivitas yang tidak memberikan nilai tambah. Waktu dari masing-masing aktivitas tersebut yang selanjutnya digunakan untuk menghitung nilai (PCE. nilai pada produk dibandingkan total waktu yang digunakan produk selama dalam proses. Berdasarkan penelitian yang telah dilakukan, didapatkan nilai PCE awal dari industri “Mi Lethek” sebesar 12,05 %Perbaikan yang dilakukan ialah dengan mengubah tata letak pabrik dan melakukan perbaikan penjadwalan pemesanan bahan baku. Hasil perbaikan tersebut berhasil meningkatkan nilai PCE menjadi 15,68 %. Kata kunci: Pemborosan, “Mi Lethek”
Jørgensen, Frances; Matthiesen, Rikke; Nielsen, Jacob
. A framework for describing levels of lean capability is presented, based on a brief review of the literature and experiences from 12 Danish companies currently implementing lean. Although still in its emerging phase, the framework contributes to both theory and practice by describing developmental stages......Although lean is rapidly growing in popularity, its implementation is far from problem free and companies may experience difficulties sustaining long term success. In this paper, it is suggested that sustainable lean requires attention to both performance improvement and capability development...... that support lean capability development and consequently, lean sustainability....
Hasle, Peter; Nielsen, Anders Paarup; Edwards, Kasper
Lean is widely applied in hospitals, but the impact tends to be limited. This paper investigates three possible explanations: 1) maturity, 2) complexity, and 3) the value concept and analyses the bearing of these in a case study of lean application in a large Danish university hospital. The results...... indicate that lean tends to be applied in secondary and support functions with a logistic character and therefore has had a limited impact on the overall healthcare performance. The case study shows that there are constraints related to low lean maturity, the complexity of processes and operations as well...... in hospitals in order to bring about a larger impact. It is therefore necessary to develop new models for the lean concept as well as the implementation of lean adapted to the particular context of hospitals with a stronger focus on patient experiences and on coordination of social relations....
Weller, Harold N; Nirschl, David S; Petrillo, Edward W; Poss, Michael A; Andres, Charles J; Cavallaro, Cullen L; Echols, Martin M; Grant-Young, Katherine A; Houston, John G; Miller, Arthur V; Swann, R Thomas
The application of parallel synthesis to lead optimization programs in drug discovery has been an ongoing challenge since the first reports of library synthesis. A number of approaches to the application of parallel array synthesis to lead optimization have been attempted over the years, ranging from widespread deployment by (and support of) individual medicinal chemists to centralization as a service by an expert core team. This manuscript describes our experience with the latter approach, which was undertaken as part of a larger initiative to optimize drug discovery. In particular, we highlight how concepts taken from the manufacturing sector can be applied to drug discovery and parallel synthesis to improve the timeliness and thus the impact of arrays on drug discovery.
Full Text Available The objective of this research was to study and improve the manufacturing process of agricultural equipment to reduce wastes by using the LEAN tools: a case study of agricultural machinery company. This study found that the main wastes were inefficiency of transportation and working process. The Systematic Layout Planning Pattern (SLP had been applied. Moreover, the principles of ECRS, the change in input factors (a number of employees, together with simulation and the Analysis Hierarchy Process (AHP were also used to determine the appropriate plant layout alternatives by considering the factors such as the productivity, materials handling distance, facilities utilization, and space utilization. The result shared that the best suitable layout is the layout No. 1. Then more improvement the layout No. 1 with the ECRS and the change of input factors (the amount of employees ,it was found that increased productivity by 16.10%, increased facilities utilization by 15.73% and decreased materials handling distance by 48.12%. Furthermore, the number of employees and the average time of workpiece in system could be reduced from 7 to 6 persons, and 54.41 minutes to 45.65 minutes respectively.
Integrando a promoção das metodologias Lean Manufacturing e Six Sigma na busca de produtividade e qualidade numa empresa fabricante de autopeças Integrating the promotion of Lean Manufacturing and Six Sigma methodologies in search of productivity and quality in an auto parts manufacturer
Iris Bento da Silva
Full Text Available Dentre os diversos fatores críticos de sucesso que as empresas devem considerar, destaca-se a busca por padrões cada vez mais elevados de produtividade e qualidade. Neste contexto, o objetivo deste trabalho é apresentar uma iniciativa de integrar a promoção das metodologias Lean Manufacturing e Six Sigma na busca de um melhor desempenho operacional. Essa integração combina a aplicação de elementos de Lean Manufacturing, que visa à racionalização dos fluxos de valor por meio da redução de desperdícios, com elementos de Six Sigma, que visa à sistematização do processo de análise e controle da variação em processos para se obter qualidade superior. O trabalho é baseado num estudo de caso sobre as mudanças realizadas para a acomodação desta abordagem numa empresa fabricante de autopeças. São investigados a estrutura adotada para sua promoção bem como o modo em que os projetos de melhoria são desenvolvidos por meio dela. Os resultados obtidos indicam que a iniciativa de conciliar a aplicação destas duas metodologias pode contribuir para aprimorar e tornar mais abrangente e efetivo o processo de melhoria contínua.Among the diverse critical success factors that the firms must consider, the pursuit of increasingly higher standards of productivity and quality stands out. In this context, the purpose of this article is to present an initiative to integrate the promotion of the Lean Manufacturing and Six Sigma methodologies in seeking enhanced operational performance. This integration combines the application of Lean Manufacturing elements that aim at the streamlining of value streams by the elimination of wastes with Six Sigma elements which aim at the systematization of the analysis and control of process variation for accomplishing superior quality. This work is based on a case study on the changes undertaken for the implementation of this approach in an auto parts manufacturer. The organizational structure which was
Muhammad Desryadi Ilyas
Full Text Available PT. Molindo Raya Industrial merupakan perusahaan penghasil pupuk organik P-126 yang berlokasi di Lawang, Kabupaten Malang dengan kapasitas produksi lebih dari 10.000 ton per tahun. Untuk memenangkan persaingan di bidang produksi pupuk organik, perusahaan dituntut untuk melakukan peningkatan kualitas proses produksi secara berkelanjutan dengan mereduksi waste yang ada. Meskipun produksi pupuk organik P-126 di PT. Molindo Raya Industrial mengalami peningkatan, namun masih terdapat beberapa waste, diantaranya waiting yang disebabkan oleh breakdown mesin produksi yang mengakibatkan kerugian perusahaan lebih dari Rp. 500.000.000 per tahun. Waste kedua ialah defect berupa granul yang tidak memenuhi spesfikasi diameter, material hasil cleaning dan karung finished good yang sobek dan waste ketiga ialah over production yang mengakibatkan kerugian perusahaan lebih dari Rp. 400.000.000 per tahun. Untuk mengatasi permasalahan tersebut dilakukan perbaikan dengan menggunakan metode lean manufacturing yang fokus dalam mereduksi waste dan non value added activity. Pada penelitian ini menggunakan framework DMIC six sigma, tahapan pertama ialah tahap define untuk mengidentifikasi permasalahan dengan menggunakan tools Big Picture Mapping, Activity Classification dan identifikasi waste berdasarkan E-DOWNTIME. Tahapan kedua ialah measure yang digunakan untuk mengukur kerugian perusahaan yang diakibatkan adanya waste. Selanjutnya adalah tahap analyze menggunakan tools 5 Why’s dan FMEA untuk mengetahui root cause adanya waste, kemudian tahap terakhir ialah tahap improve, pada tahap improve dilakukan penyusunan dan pemilihan alternatif usulan perbaikan dengan mengunakan pendekatan value engineering. Usulan perbaikan terpilih dalam upaya meningkatkan proses produksi pupuk organik P-126 diantaranya mengevaluasi penjadwalan preventif maintenance mesin produksi, menyusun penjadwalan mesin produksi yang kritis, evaluasi SOP dan penerapan SOP, melaksanakan pelatihan untuk
Tiago Augusto Amarante de Souza
Full Text Available In this study, the production chain of a manufacturing company of aluminum electrical conductors is analyzed, in order to select the best strategy for increasing its production capacity. The company´s production systems and flows are highly complex and have high variability in their production flows. A quantitative modeling methodology was proposed to simulate those systems, and to analyze them in a simpler manner. The simulation model considered two different strategies related to production increase: “Lean Thinking” and Machinery/Equipment Purchase. From the current context and the results obtained from the simulation study, it was possible to conclude that the best scenario for increasing production capacity for the company was using the Lean Thinking strategy on the critical processes.The gains in capacity are higher and the implementing costs involved are lower than the ones observed in the other strategy considered.
Womack, James P; Jones, Daniel T
During the past 20 years, the real price of most consumer goods has fallen worldwide, the variety of goods and the range of sales channels offering them have continued to grow, and product quality has steadily improved. So why is consumption often so frustrating? It doesn't have to be--and shouldn't be--the authors say. They argue that it's time to apply lean thinking to the processes of consumption--to give consumers the full value they want from goods and services with the greatest efficiency and the least pain. Companies may think they save time and money by off-loading work to the consumer but, in fact, the opposite is true. By streamlining their systems for providing goods and services, and by making it easier for customers to buy and use those products and services, a growing number of companies are actually lowering costs while saving everyone time. In the process, these businesses are learning more about their customers, strengthening consumer loyalty, and attracting new customers who are defecting from less user-friendly competitors. The challenge lies with the retailers, service providers, manufacturers, and suppliers that are not used to looking at total cost from the standpoint of the consumer and even less accustomed to working with customers to optimize the consumption process. Lean consumption requires a fundamental shift in the way companies think about the relationship between provision and consumption, and the role their customers play in these processes. It also requires consumers to change the nature of their relationships with the companies they patronize. Lean production has clearly triumphed over similar obstacles in recent years to become the dominant global manufacturing model. Lean consumption, its logical companion, can't be far behind.
This Guide focuses primarily on Lean production, which is an organizational improvement philosophy and set of methods that originated in manufacturing but has been expanded to government and service sectors.
Bertholey, F; Bourniquel, P; Rivery, E; Coudurier, N; Follea, G
Continuous improvement of efficiency as well as new expectations from customers (quality and safety of blood products) and employees (working conditions) imply constant efforts in Blood Transfusion Establishments (BTE) to improve work organisations. The Lean method (from "Lean" meaning "thin") aims at identifying wastages in the process (overproduction, waiting, over-processing, inventory, transport, motion) and then reducing them in establishing a mapping of value chain (Value Stream Mapping). It consists in determining the added value of each step of the process from a customer perspective. Lean also consists in standardizing operations while implicating and responsabilizing all collaborators. The name 5S comes from the first letter of five operations of a Japanese management technique: to clear, rank, keep clean, standardize, make durable. The 5S method leads to develop the team working inducing an evolution of the way in the management is performed. The Lean VSM method has been applied to blood processing (component laboratory) in the Pays de la Loire BTE. The Lean 5S method has been applied to blood processing, quality control, purchasing, warehouse, human resources and quality assurance in the Rhône-Alpes BTE. The experience returns from both BTE shows that these methods allowed improving: (1) the processes and working conditions from a quality perspective, (2) the staff satisfaction, (3) the efficiency. These experiences, implemented in two BTE for different processes, confirm the applicability and usefulness of these methods to improve working organisations in BTE.
Hasle, Peter; Jensen, Per Langaa
The consequences for quality of work of lean manufacturing is discussed in the international litterature, and several authors suggest increased work speed, stress, and muscoskeletal diseases as a consequence of lean. The Danish experience with lean has been studied through interviews with managers...
Et nyligt afsluttet forskningsprojekt mellem DTU, Aalborg Universitet, det Nationale forskningscenter for arbejdsmiljø og 10 danske virksomheder konkluderer at lean ikke betyder forringelse af arbejdsmiljøet. Projektet konkluderer også at ledelse er afgørende og at forandringsprocessen er hård...
Ricardo Aurélio Quinhões Pinto
Full Text Available Esta pesquisa tem como objetivo analisar o impacto da filosofia lean aplicada à gestão de estoque como diferencial de desempenho e vantagem competitiva em uma empresa metalúrgica. Trata-se de um estudo de caso descritivo, ex-post facto e de corte temporal seccional. Este estudo demonstra que após a implementação da filosofia lean, a empresa obteve maior interatividade na administração da informação entre os elementos internos e externos, o que permitiu a redução dos custos de produção, melhorias na qualidade dos produtos e eliminação dos grandes estoques de segurança sem comprometimento do nível de serviço oferecido ao cliente.
Osezua Aikhuele, Daniel; Mohd Turan, Faiz
The instability in today's market and the emerging demands for mass customized products by customers, are driving companies to seek for cost effective and time efficient improvements in their production system and this have led to real pressure for the adaptation of new developmental architecture and operational parameters to remain competitive in the market. Among such developmental architecture adopted, is the integration of lean thinking in the product development process. However, due to lack of clear understanding of the lean performance and its measurements, many companies are unable to implement and fully integrate the lean principle into their product development process and without a proper performance measurement, the performance level of the organizational value stream will be unknown and the specific area of improvement as it relates to the LPD program cannot be tracked. Hence, it will result in poor decision making in the LPD implementation. This paper therefore seeks to present a conceptual model for evaluation of LPD performances by identifying and analysing the core existing LPD enabler (Chief Engineer, Cross-functional teams, Set-based engineering, Poka-yoke (mistakeproofing), Knowledge-based environment, Value-focused planning and development, Top management support, Technology, Supplier integration, Workforce commitment and Continuous improvement culture) for assessing the LPD performance.
Jeppesen, Hans Jeppe; Jønsson, Thomas
Gennem det seneste årti har brug af teams som en måde at organisere arbejdet på været i hastig fremmarch. Det er baggrunden for forskningsprojektet ”Team-organiseringens betydning for participation og organisatoriske relationer”, der er et multiple case-studie af seks organisationers brug af...... teamwork. Bag projektet står professor Hans Jeppe Jeppesen, cand.psych. og ph.d. Thomas Rasmussen samt adjunkt Thomas Jønsson. I denne klumme gives en forskningsbaseret introduktion til teamarbejdet og dets betydning for samspillet mellem medarbejdere og organisation. Med udgangspunkt i egen forskning...
Most enterprises inducting lean production were confined by the innate limitations of existing production systems, which make it difficult to fulfill lean production comprehensively. To solve this problem, the theory of lean design and management for the manufacturing enterprise lifecycle was proposed. First, the necessities of lean design were analyzed and its theoretical system was established; second, the principles, process, methods and tools for lean design was introduced. Techniques and...
Ford, Andria L.; Williams, Jennifer A.; Spencer, Mary; McCammon, Craig; Khoury, Naim; Sampson, Tomoko; Panagos, Peter; Lee, Jin-Moo
Background Earlier tPA treatment for acute ischemic stroke increases efficacy, prompting national efforts to reduce door-to-needle times (DNTs). We utilized lean process improvement methodology to develop a streamlined IV tPA protocol. Methods In early 2011, a multi-disciplinary team analyzed the steps required to treat acute ischemic stroke patients with IV tPA, utilizing value stream analysis (VSA). We directly compared the tPA-treated patients in the “pre-VSA” epoch to the “post-VSA” epoch with regard to baseline characteristics, protocol metrics, and clinical outcomes. Results The VSA revealed several tPA protocol inefficiencies: routing of patients to room, then to CT, then back to room; serial processing of work flow; and delays in waiting for lab results. On 3/1/2011, a new protocol incorporated changes to minimize delays: routing patients directly to head CT prior to patient room, utilizing parallel process work-flow, and implementing point-of-care labs. In the pre-and post-VSA epochs, 132 and 87 patients were treated with IV tPA, respectively. Compared to pre-VSA, DNTs and percent of patients treated ≤60 minutes from hospital arrival were improved in the post-VSA epoch: 60 min vs. 39 min (pLean process improvement methodology can expedite time-dependent stroke care, without compromising safety. PMID:23138440
S. Kolanjiappan; Dr. K. Maran
Lean Maintenance is a relatively new term, invented in the last decade of the twentieth century, but the principles are well established in Total Productive Maintenance (TPM). Lean Maintenanceâ€”taking its lead from Lean Manufacturingâ€”applies some new techniques to TPM concepts to render a more structured implementation path. Tracing its roots back to Henry Ford with modern refinements born in Japanese manufacturing, specifically the Toyota Production System (TPS). Lean seeks to eliminate a...
Full Text Available Introducción: Este artículo presenta una propuesta de mejora en el tiempo de atención al paciente mediante el uso de la metodología de Lean Manufacturing en una unidad de urgencias en una clínica en Bogotá, la cual incumple o excede los estándares de tiempo para atención al paciente establecidos por la Secretaría Distrital de Salud. Método: Este trabajo de investigación se realizó en una Institución Prestadora de Servicios de Salud (IPS, universitaria, privada, sin ánimo de lucro, ubicada en Bogotá- Colombia. El diseño de investigación es de tipo no experimental, transversal y descriptiva, mediante un trabajo en campo de 6 meses con el fin de establecer las áreas y/o procesos que no agregan valor al paciente, mediante el uso de herramientas propias del Lean Manufacturing tales como el value stream mapping y el diagrama de spaghetti, generando planes de acción que contribuyeran a la mejora en los tiempos de atención al paciente. Resultados: Las actividades o mudas que no generan valor al cliente y que requieren ser mejoradas o eliminadas, en la unidad de urgencias estudiada, hacen alusión a:  Registros en admisiones,  esperas en el ingreso para valoración a triage, ortopedia, consulta y tratamiento médico y  la entrega de la orden de salida.La aplicabilidad de la propuesta se evaluó a través de simulaciones basadas en el Software Arena, obteniendo mejoras en los tiempos de espera del paciente de hasta un 67%. Discusión o Conclusión: Este proyecto evidencia mejoras en los tiempos de espera para la atención al paciente en la Unidad de Urgencia estudiada, lo cual podría incentivar el uso del Lean en otras unidades o IPS a nivel Colombia o América Latina, ya que se establece que esta área de investigación aún es incipiente en dichas regiones.
Giuliano Almeida Marodin
Full Text Available The main purpose of lean production (LP is to produce more with fewer resources, for example less people, space, time and stock. The lesser quantity of resources on the production system increases the demand for greater quality and flexibility to the internal logistics. However, the amount of articles on the subject is sparse and mainly focused on the first steps of the implementation process. This article had the following objectives: to analyze the internal logistic of a plant that already uses LP practices, to propose and to implement improvements. The method used was an action research that adapts the Harris et al. (2004 guidelines to be used on a company that already use LP practices. As results, the study allowed the solution of several problems before the implementation of the new routes. As results for the company, there were several process improvements, as well as the reduction of direct logistics costs and improvement of the work balancing among routes.
Full Text Available In the paper, the method of the production process improvement with the use of lean production tools has been presented. The Value Stream Mapping (VSM for the cardboard packaging produc-tion process has been presented. On the basis of the current state map (CSM, areas for improvement have been designated - 5 organizational changes of the process were marked out. To minimize the three basic losses excessive storage, unnecessary movement and delays, the changes were introduced in the method of inter-operative transport, supervision of the storage condition (input and output of the process, control at the processing operation and the use of a production loop. As a result of the changes, it is possible to shorten the process time, shorten the total time of operations adding value and reduce the number of non-compliant products.
Jespersen, Per T; Vesterager Christensen, D; Andersen, Hans [Teknologisk Institut, Energi og Klima, Taastrup (Denmark); Dam Wied, M; Dam, M [NRGi Raadgivning, Aarhus (Denmark); Thorndahl, M [Horsens Kommune, Horsens (Denmark); Weldingh, P [Lokal Energi, Viby J. (Denmark); Maagoee, P; Kristensen, Kenneth T [Viegand og Maagoee, Copenhagen (Denmark); Kirketerp Friis, A [Novozymes, Bagsvaerd (Denmark)
By means of theoretical reports and three specific cases, the project showed how Lean principles can improve energy consulting efficiency, thus making it easier for end-users and energy consultants to record and document energy savings achieved. The three cases documented various types of extra benefits of integrating energy efficiency improvement in Lean processes. As a result of process optimisation, one manufacturing company successfully reduced both staffing and energy consumption, thus making production in Denmark competitive with out-sourced production in Asia. (LN)
Tsasis, Peter; Bruce-Barrett, Cindy
In production and manufacturing plants, Lean Thinking has been used to improve processes by eliminating waste and thus enhancing efficiency. In health care, Lean Thinking has emerged as a comprehensive approach towards improving processes embedded in the diagnostic, treatment and care activities of health-care organizations with cost containment results. This paper provides a case study example where Lean Thinking is not only used to improve efficiency and cost containment, but also as an approach to effective organizational change.
Nikolou-Walker, Elda; Lavery, Kathy
Globalisation has had a major impact on the engineering industry as Pacific Rim countries undercut manufacturing costs and provide a more cost-effective location for many businesses. Engineering in Northern Ireland has mostly declined owing to increased competition from these countries. Engineering companies are now forced to streamline their…
Gonzalo Emilio León
Full Text Available La investigación del presente documento pretendió identificar en cinco empresas de diferentes sectores de la economía, en Colombia, cuáles han sido los factores claves que han permitido implementar con éxito herramientas de Manufactura Esbelta o Lean Manufacturing. Estas herramientas surgen de la filosofía japonesa, que pretende hacer más con menos, eliminando todo tipo de desperdicios en materiales y recursos; mediante la aplicación de diferentes herramientas administrativas y de producción que incluye entre otras, la mejora continua. Se entiende por desperdicio, todas aquellas actividades que no aportan valor al producto y por las cuales el cliente no está dispuesto a pagar. Se buscó identificar también cuales han sido sus principales logros y barreras en la implementación, a partir de una investigación de aspectos cualitativos mediante la metodología de estudio de caso. Se encontró que el compromiso de los dueños y directivos, el liderazgo visto desde las competencias Lean, el cuidadoso diseño de indicadores y su seguimiento y el entrenamiento en la filosofía y operación, son esenciales a la hora de realizar la implementación; estos ayudaron en la mejora de aspectos relevantes como la productividad y rentabilidad. En algunas, la implementación exitosa, permitió extender su aplicación a sus proveedores más importantes.
Long, John C
Lean Thinking is an integrated approach to designing, doing and improving the work of people that have come together to produce and deliver goods, services and information. Healthcare Lean is based on the Toyota production system and applies concepts and techniques of Lean Thinking to hospitals and physician practices.
Riis, Jens Ove; Mikkelsen, Hans; Andersen, Jesper Rank
The notion of Lean Manufacturing is not merely confined to a set of well defined techniques, but represents a broad approach to managing a company. Working with lean entails many aspects, such as production planning and control, production engineering, product development, supply chain......, and organizational issues. To become effective, many functional areas and departments must be involved. At the same time companies are embedded in a dynamic environment. The aim of the paper is to propose a comprehensive approach to better implementation of lean initiatives, based on two empirical studies. The paper...... will discuss how a concerted effort can be staged taking into account the interdependencies among individual improvement initiatives. The notion of orchestration will be introduced, and several means for orchestration will be presented. Critical behavioral issues for lean implementation will be discussed....
Lean, with its origins at the Toyota Motor Company, is a concept that is known to increase effectiveness in manufacturing. The Lean concept is now argued to be relevant not only in manufacturing but in service and health-care delivery as well. The reported results of Lean implementation efforts are divided. There are reports that most of the Lean implementation efforts are not reaching the goal; on the other hand, there are reports of promising results. The divided results from Lean implement...
Santosa W. A.
Full Text Available PT. XY produces musical instruments such as Upright Pianos and Grand Pianos. Due to a competitive competition, a good quality product is highly required as well as increasing the production scale. To achieve these objectives, company needs to reduce wastes occurred in its production lines, particularly in the division of sanding panel upright piano (UP which produces type of PE B1 pianos. High cycle time and lead-time are caused by wastes in UP panel sanding division. Therefore, it is needed improvements to be applied here so that the production lines will be run more effectively and efficiently. This study aims to identify wastes using Value Stream Mapping (VSM as a tool of lean manufacturing and to implement the improvements using Kaizen. It is found that the wastes are motion and waiting. Furthermore, the improvements (kaizen are focused on reducing motion and waiting wastes. It is shown that cycle time decreased from 51.16 minutes to 41.90 minutes, work in process or inventory can be reduced to 24 pcs over 32 pcs, and the lead-time is 0.167 days of 0.222 days.
Full Text Available This research aimed at identifying the wastes of plywood production in PT Sumber MasIndah Plywood. Results were then utilized to determine methods in reducing wastes. Theidentification of waste was carried out using lean manufacturing approach. The data werecollected from manufacturer records, study to determine processing time, as well as interviewand quisioners which were distributed to workers in each department. Big picture mapping andvalue stream mapping tools (VALSAT were then utilized to process the data. Results ofanalyses using big picture mapping showed that total production lead time was 438,8 minutes,with 235,97 minutes of them were value added activities; and 27 days of total information leadtime. Workshop waste analyses resulted in the highest waste generated during plywoodproduction process. Those were 133 waiting time (delay, 113 defect and 78 excessivetransportation. Further analyses using VALSAT showed three methods to identify the data inmore detail, namely process activity mapping (PAM, supply chain response matrix (SCRMand quality filter mapping (QFM. Results from PAM method revealed 125 activities duringproduction, consist 62 value added activities, 33 necessary but non value added activities and 30non value added activities. While results from SCRM showed the average 22,63 days of totalorder fulfillment process comprised of 4,13 days of total physical stock and 18,5 days of totallead time. QFM result showed ratio of scrap defect reject 0,4% and ratio of scrap defect UTY3,46%. In general waste in plywood production at PT Sumber Mas Indah Plywood wasgenerated from worker, material, machinery, methods and environment. One of the ways toimprove it is by applying pull system (Kanban
Over the past 20 years Lean Production system has been a focus of researches by different academicians. A numerous works have been written in the field of Lean implementation in manufacturing companies. However, as shown, most of the academic topics relate to the issues of implementing Lean tools and techniques. Critical Success Factors have been also described widely; however, no efforts in systematization have been made. Only several works have a focus on integration of Lean implementation ...
Swank, Cynthia Karen
Jefferson Pilot Financial, a life insurance and annuities firm, like many U.S. service companies at the end of the 1990s was looking for new ways to grow. Its top managers recognized that JPF needed to differentiate itself in the eyes of its customers, the independent life-insurance advisers who sell and service policies. To establish itself as these advisers' preferred partner, it set out to reduce the turnaround time on policy applications, simplify the submission process, and reduce errors. JPF's managers looked to the "lean production" practices that U.S. manufacturers adopted in response to competition from Japanese companies. Lean production is built around the concept of continuous-flow processing--a departure from traditional production systems, in which large batches are processed at each step. JPF appointed a "lean team" to reengineer its New Business unit's operations, beginning with the creation of a "model cell"--a fully functioning microcosm of JPF's entire process. This approach allowed managers to experiment and smooth out the kinks while working toward an optimal design. The team applied lean-manufacturing practices, including placing linked processes near one another, balancing employees' workloads, posting performance results, and measuring performance and productivity from the customer's perspective. Customer-focused metrics helped erode the employees' "My work is all that matters" mind-set. The results were so impressive that JPF is rolling out similar systems across many of its operations. To convince employees of the value of lean production, the lean team introduced a simulation in which teams compete to build the best paper airplane based on invented customer specifications. This game drives home lean production's basic principles, establishing a foundation for deep and far-reaching changes in the production system.
The goal of this Bachelor's Thesis is to describe the general principles of lean production and afterwards apply these principles in a particular company. Due to the changing conditions on the world market is among companies growing concern about such innovative business systems. The theoretical part of this work deals with the general characteristics of lean production, including their history and focus on Toyota, as the originator of most lean systems. Mentioned are also the economic aspect...
Rahbek Pedersen, Esben; Muniche, Mahad
Purpose – The purpose of this paper is to analyse how negotiations between the constituencies affect the processes and outcomes of lean projects in Danish public sector organisations. Design/methodology/approach – The paper is based on a qualitative analysis of interviews with managers...... projects in the Danish public sector. It cannot be concluded that the findings can be generalised to reflect all types of lean projects across organisational and geographical settings. Originality/value – The paper adds value to the relatively scarce literature on lean management in the public sector...... and employees who have participated in lean projects in the Danish public sector. Negotiated order theory serves as the overarching theoretical framework for the analysis. Findings – The paper concludes that the processes and outcomes of lean depend not only on the technology itself, but also the negotiation...
The purpose of this paper is to show how over the last 18 months Bolton Hospitals NHS Trust have been exploring whether or not lean methodologies, often known as the Toyota Production System, can indeed be applied to healthcare. This paper is a viewpoint. One's early experience is that lean really can save lives. The Toyota Production System is an amazingly successful way of manufacturing cars. It cannot be simply translated unthinkingly into a hospital but lessons can be learned from it and the method can be adapted and developed so that it becomes owned by healthcare staff and focused towards the goal of improved patient care. Working in healthcare is a stressful and difficult thing. Everyone needs a touch of inspiration and encouragement. Applying lean to healthcare in Bolton seems to be achieving just that for those who work there.
Wijnhoven, Alphonsus B.J.M.; Beckers, David; Amrit, Chintan Amrit
In the last few decades, lean techniques have been developed for removing with waste in manufacturing. More recently, lean is used outside the manufacturing context as well. This article focuses on using lean thinking for reducing waste in administrative services, i.e., business services with
Boje, Thomas P.; Ejrnæs, Anders
Kapitlet beskriver og diskuterer de strategier, som bliver anvendt i familiepolitikken i Danmark såvel som i udvalgte europæiske lande med det formål at sikre en bedre ligevægt mellem de krav, som stilles til forældrene i arbejdslivet og i familien i form af omsorg for børn. Kapitlet afsluttes me...... beskrivelse af en familiepolitisk typologi, og hvordan relationen mellem familie og arbejde kommer til udtryk i de forskellige europæiske velfærdsregimer....
Hjelmar, Ulf; Bhatti, Yosef; Vrangbæk, Karsten
I en ny forskningsrapport sammenlignes kvaliteten på tværs af offentlige og private plejehjem i Danmark. Rapporten finder interessante forskelle mellem offentlige og private udbydere men konkluderer overordnet, at lighederne generelt er større end forskellene.......I en ny forskningsrapport sammenlignes kvaliteten på tværs af offentlige og private plejehjem i Danmark. Rapporten finder interessante forskelle mellem offentlige og private udbydere men konkluderer overordnet, at lighederne generelt er større end forskellene....
Qi, Ang Nian; Sin, Tan Chan; Fathullah, M.; Lee, C. C.
Fit manufacturing and Green manufacturing are a new trend principle and concept. They are getting popular in industrial. This paper is identifying the impact between Fit manufacturing and Green manufacturing. Besides Fit manufacturing, Lean manufacturing, Agile manufacturing and Sustainable manufacturing gives big impacts to Green Manufacturing. On top of that, this paper also discuss the benefits of applying Fit manufacturing and Green manufacturing in industrial as well as environment. Hence, applications of Fit manufacturing and Green Manufacturing are increasing year by year.
Riezebos, Jan; Klingenberg, Warse; Hicks, Christian
The principles of Lean Production have enabled organisations in the manufacturing and service sectors to significantly improve their competitiveness. The application of Lean principles, derived from the Toyota Production System has enabled many organisations to Simultaneously improve productivity,
In this article the possibility of increase of competitiveness of the domestic enterprises by means of Lean management system is considered, and also the analysis of introduction of the mentioned system at the Russian enterprises is carried out. Besides, the key conditions necessary for successful introduction of system are presented. Lean management is a world-spread way of solving the problems, aimed at making the company competitive; it is the organized activity of staff of the company, fo...
Buhl, Kenneth Øhlenschlæger
Konflikten mellem Ukraine og Rusland udgør en trussel mod den internationale retsorden og dermed også hele den europæiske orden. Med henblik på at give et grundlag for at forstå omfanget af dette aspekt af konflikten behandles her lovligheden af nogle af de handlinger, som har været konfliktens...
Daniel D. GEORGESCU
The goal of lean maintenance approach is to maintain organization international competitiveness. In the spirit of continuously improvement, in the paper it is shown how by adjusting some Lean manufacturing specific techniques for Total Productive Maintenance (TPM) system, was born new maintenance system named Lean TPM. This is a systemic approach with three techniques, which don’t exclude specific techniques of TPM pillars, but complete them: the 7Ss as a critical first step in any improvemen...
Full Text Available Many organizations, dealing with continuous improvement methods, have realized that Lean and Six Sigma methodologies complement each other. Lean manufacturing focuses on the remova l of waste so that all processes in the total system add value from the customers' perspectives. The main emphasis of Six Sigma is the application of statistical tools in a disciplined manner, which requires data-driven decision-making. The integration of Lean and Six Sigma provides a synergetic effect, a rapid process improvement strategy for attaining organizational goals. When separated, Lean manufacturing cannot bring a process under statistical control, and Six Sigma cannot dramatically improve cycle time or reduce invested capital. Together, synergistic qualities are created to maximize the potential for a process improvement. The paper deals with Lean and Six Sigma principles and approaches used in modern manufacturing for process improvements, and bring forward benefits that are gained when these two methodologies are integrated.
Due to increased pressure from global competitors, manufacturing organizations are switching over to lean philosophies from traditional mass production. Lean manufacturing is a manufacturing philosophy which focuses on elimination of various types of wastes and creates maximum value for the end customers. Lean thinking aims to produce high quality products and services at the lowest possible cost with maximum customer responsiveness. Indian Industry is facing lot of problems in this transform...
Hence, this study aims to examine the influence of leadership style in the implementation of lean production. Data were gathered from randomly selected Malaysian manufacturing firms. Findings reveal a positive relationship between lean production and business performance. Specifically, democratic leadership style was ...
As healthcare organizations look for new and improved ways to reduce costs and still offer quality healthcare, many are turning to the Toyota Production System of doing business. Rather than focusing on cutting personnel and assets, "lean healthcare" looks to improve patient satisfaction through improved actions and processes.
R. M. Torielli
Full Text Available Lean manufacturing is often seen as a set of tools that reduce the total cost and improve the quality of manufactured products. The lean management philosophy is one which targets waste reduction in every facet of the manufacturing business; however, only recently have studies linked lean management philosophies with improving environmental sustainability. These studies suggest that lean manufacturing is more than a set of lean tools that can optimize manufacturing efficiencies; it is a process and mindset that needs to be integrated into daily manufacturing systems to achieve sustainability. The foundry industry, as well as manufacturing in general, has significant challenges in the current regulatory and political climate with developing an economically and environmentally sustainable business model. Lean manufacturing has proven itself as a model for both economic sustainability and environmental stewardship. Several recent studies have shown that both lean and green techniques and “zero-waste” policies also lead to reductions in overall cost. While these strategies have been examined for general manufacturing, they have not been investigated in detail for the foundry industry. This paper will review the current literature and describe how lean and green can provide a relevant framework for environmentally and economically sustainable foundries. Examples of lean and green technologies and techniques which can be applied to foundries in a global context will be described.
Eka Ardhani Sisdyani
Full Text Available Manufacturing techniques have been developed to embrace theaims of continuous improvement. Continuous improvement would leadcompanies to win business competition. One technique that gains moreand more followers is lean manufacturing. Lean manufacturing hastwo main purposes, which are eliminating wastes and creating valuesto customers. It focuses on customer values, value stream, productionflows, demand-pull, and perfection. Lean accounting is needed tosupport and encourage the development of lean manufacturing, forinstances in product costing system, external reporting, and otherdecision making processes that need accounting data.
Full Text Available In the paper basic concepts of Lean Manufacturing were presented. A company specializing in the development of vehicle dynamics, driver assistance systems, brake systems, seat belt sand electronics technology was characterized. The company is engaged in designing and manufacturing world-class products for the automotive market. The Lean tools used in the production hall, such as Yamazumi chart, machine motion analysis, MTM method and timing, were presented.
Manuela Ingaldi; Marta Jagusiak-Kocik
In the paper basic concepts of Lean Manufacturing were presented. A company specializing in the development of vehicle dynamics, driver assistance systems, brake systems, seat belt sand electronics technology was characterized. The company is engaged in designing and manufacturing world-class products for the automotive market. The Lean tools used in the production hall, such as Yamazumi chart, machine motion analysis, MTM method and timing, were presented.
Daniel D. GEORGESCU
Full Text Available The goal of lean maintenance approach is to maintain organization international competitiveness. In the spirit of continuously improvement, in the paper it is shown how by adjusting some Lean manufacturing specific techniques for Total Productive Maintenance (TPM system, was born new maintenance system named Lean TPM. This is a systemic approach with three techniques, which don’t exclude specific techniques of TPM pillars, but complete them: the 7Ss as a critical first step in any improvement program; instantaneous maintenance; improvement setup operations. In the spirit of Lean principle, Lean TPM adjusts overall equipment effectiveness concept for all supply-chain from supplier to customer. Maintaining equipment in its optimal state and continually improving its productivity is the whole strategy behind Lean TPM.
James E. Grunig
Full Text Available I forsommeren 1993 tildelte Dansk Public Relations Forening årets PR- pris til mesterkommunikatøren Lars Larsen, Jysk Sengetøjslager/Larsen Rejser. I motiveringen hedder det, at Lars Larsen hædres for "en prisvær- dig Public Relations indsats, der kan motivere til en øget anvendelse af Public Relations i den danske forretningsverden". Blandt PR-foreningens medlemmer vakte pristildelingen en vis furore; et indlæg i foreningens blad PRspektiv invendte, at Lars Larsen driver "publicity" (dvs. et reklame- værktøj - "Præcis den slags PR, som vi i mange år har arbejdet på at distancere Public Relation-begrebet fra". Lars Larsen selv sagde, at han slet ikke skelner mellem Public Relations, PR og markedsføring. Et andet indlæg i bladet argumenterede for, at det ikke længere giver mening at adskille begreberne Public Relations og markedsføring, fordi grænsen mellem det offentlige og det private ude i virkeligheden er mere og mere flydende. James Grunigs artikel, der søger at afklare forholdet mellem PR og marketing teoretisk og praktisk, er derfor brændende aktuelt, ikke mindst for PR-fagets bestræbelser på at blive anerkendt som en respek- tabel profession. Den blev præsenteret som foredrag under Grunigs Dan- marksbesøg i marts 1993, er redigeret af Kim Schrøder og oversat fra engelsk af Kenja Henriksen.
Adapting the 'Lean' methodologies used for many years by many manufacturers on the production line - such as in the automotive industry - and deploying them in healthcare 'spaces' can, Roger Call, an architect at Herman Miller Healthcare in the US, argues, 'easily remedy many of the inefficiencies' found within a healthcare facility. In an article that first appeared in the September 2013 issue of The Australian Hospital Engineer, he explains how 'Lean' approaches such as the 'Toyota production system', and 'Six Sigma', can be harnessed to good effect in the healthcare sphere.
Referat af udenlandsk arbejde vedr. sammenhæng mellem luftvejssygdomme i tidlig barndom og senere astma. Udgivelsesdato: 1994......Referat af udenlandsk arbejde vedr. sammenhæng mellem luftvejssygdomme i tidlig barndom og senere astma. Udgivelsesdato: 1994...
Monteiro, Mónica F. J. R.; Pacheco, Claudia C. L.; Dinis-Carvalho, José; Paiva, Francisco C.
Applying lean approaches in office areas can lead to performance improvements and other benefits as achieved in traditional manufacturing environments. The intangibility of office operations may appear as a major difficulty for lean implementations but in fact the benefits achievable are as important as the ones achieved in manufacturing environments. This paper reports a successful case of lean office implementation in a public sector organization giving emphasis to its major performance imp...
Ramsøy, Thomas Z.
En meget omdiskuteret frygt for en sammenhæng mellem MFR-vaccinen og autisme er for nylig manet til jorden......En meget omdiskuteret frygt for en sammenhæng mellem MFR-vaccinen og autisme er for nylig manet til jorden...
Radnor, Zoe J; Holweg, Matthias; Waring, Justin
In an effort to improve operational efficiency, healthcare services around the world have adopted process improvement methodologies from the manufacturing sector, such as Lean Production. In this paper we report on four multi-level case studies of the implementation of Lean in the English NHS. Our results show that this generally involves the application of specific Lean 'tools', such as 'kaizen blitz' and 'rapid improvement events', which tend to produce small-scale and localised productivity gains. Although this suggests that Lean might not currently deliver the efficiency improvements desired in policy, the evolution of Lean in the manufacturing sector also reveals this initial focus on the 'tool level'. In moving to a more system-wide approach, however, we identify significant contextual differences between healthcare and manufacturing that result in two critical breaches of the assumptions behind Lean. First, the customer and commissioner in the private sector are the one and the same, which is essential in determining 'customer value' that drives process improvement activities. Second, healthcare is predominantly designed to be capacity-led, and hence there is limited ability to influence demand or make full use of freed-up resources. What is different about this research is that these breaches can be regarded as not being primarily 'professional' in origin but actually more 'organisational' and 'managerial' and, if not addressed could severely constrain Lean's impact on healthcare productivity at the systems level. Copyright © 2011 Elsevier Ltd. All rights reserved.
Full Text Available På baggrund af kognitionspsykologi og peirceansk tegnteori fremsætter artiklen et reklamesemiotisk bud på sammenhængen mellem annoncers komposition og deres virkning. Artiklen har til formål at belyse, hvorledes den trykte annonces forskellige æstetikker og kompositioner udløser for- skellige emotionelle og kognitive effekter i receptionen. Der indkredses tre receptionsmodi, der hver svarer til en bestemt annoncekompositorisk kategori. Artiklen er en videreudvikling af reklamesemiotikken, som i Dan- mark især er blevet funderet på et semiologisk grundlag. Der argumente- res for, at den semiologiske tilgang kun er delvis fyldestgørende, efter- som man her læser reklamens illustration med verbalsproget som model og derved implicit antager, at verbalsproglige og visuelle tegnsystemer har samme organisation. I modsætning til sproget mangler billedet imid- lertid den dobbelte artikulation. Artiklen forsøger at indfange disse forskel- le mellem tegnsystemer for derigennem at oparbejde et mere nuanceret blik for, i hvilket omfang forskellige reklameæstetikker faktisk udløser bestemte kognitive effekter i receptionen. Ved ’kognitive effekter’ forstås primært emotionsdannelse og inferensprocesser.
Applies lean manufacturing principles across the cloud service delivery chain to enable application and infrastructure service providers to sustainably achieve the shortest lead time, best quality, and value This book focuses on lean in the context of cloud computing capacity management of applications and the physical and virtual cloud resources that support them. Lean Computing for the Cloud considers business, architectural and operational aspects of efficiently delivering valuable services to end users via cloud-based applications hosted on shared cloud infrastructure. The work also focuses on overall optimization of the service delivery chain to enable both application service and infrastructure service providers to adopt leaner, demand driven operations to serve end users more efficiently. The book’s early chapters analyze how capacity management morphs with cloud computing into interlocked physical infrastructure capacity management, virtual resou ce capacity management, and application capacity ma...
Barnet, R J
The author attempts to take stock of five critical systems of resources: Energy, mineral resources, food, water, and human abilities. All five systems have been integrated, to an ever-increasing extent in global control systems. These control systems determine how many people, in what parts of the world, will be faced with hunger, cold, or unemployment. The author tries to find out who is in charge of these control systems, how they have come into existence, and on what strategies they are based. In the final chapter, ''Policy of survival'', the author states that the secret of survival in the lean years to come is still in the dark. Man's most fundamental desire is to be human, i.e. to be in harmony with nature both psychologically and biologically. Politics should take account of this and provide us with the means for doing what is necessary.
Full Text Available The maintenance process shares significant operating costs in an organisation. Lean thinking can be incorporated into maintenance activities through applying its principles and practices/tools. Lean maintenance (LM is a prerequisite for lean manufacturing systems. This research proposes a new structure for LM process based on a systematic literature review of a significant number of related articles that were published on LM. The process structure is designed based on the five lean principles to guide and support organisations to pursue maintenance excellence. This study establishes a scheme for LM tools that are structured into 2 level 4 bundles and 26 lean practices/tools and develops a House of Waste (HoW to demonstrate the association between maintenance wastes and the LM tools. With a successful accomplishment of the proposed scheme, the performance of a maintenance department can create more improvement opportunities over time to reach the maintenance excellence status.
Brännmark, Mikael; Langstrand, Jostein; Johansson, Stina
practices seem to overlap with other popular management concepts, such as High Performance Work Systems, World Class Manufacturing and Total Quality Management. This confusion, combined with different methodological and theoretical traditions, has led to much debate and contradictory conclusions regarding...... Lean. The purpose of the paper is to illustrate some key methodological issues that need to be considered in future Lean research to allow increased understanding of Lean effects for different stakeholders, primarily meaning the customer, employer and employees. Design/methodology/approach – The paper...... on the case studies, we suggest that future investigations describe the Lean interventions in more detail. General descriptions or analogies, e.g. ‘learning organizations’, presumably increase the present confusion regarding Lean impact on different stakeholders. The case studies also illustrate...
Full Text Available These years, manufacturing function have been transferred rapidly and globally from matured countries to emerging countries. In this paper is about the critical elements for successful transfer of lean management among sites and countries. Based on this general descriptive analysis, current global transfer activity of Lean as well as its future direction is also described. According to the gradual progress of lean management transfer, necessity of its refinement/reinforcement is recognized and some research subjects are proposed for contributing further encouragement of its global activities. In this paper, based on this understanding, requisites for transfer of lean management are discussed through investigating global activity of Lean and specification of infrastructure enabling its smooth transfer is examined
Gomes, Andreia Macedo; Vieira, Pedro Senna; Reis, Augusto da Cunha
Recently, the Lean philosophy is gaining importance due to a competitive environment, which increases the need to reduce costs. Lean practices and tools have been applied to manufacturing, services, supply chain, startups and, the next frontier is healthcare. Most lean techniques can be easily adapted to health organizations. Therefore, this paper intends to summarize Lean practices and tools that are already being applied in health organizations. Among the numerous techniques and lean tools ...
Mouyal, Lone Wandahl
Det traktatbaserede regime til beskyttelse af udenlandsk investering har de seneste år været genstand for kritik, der dækker over en grundlæggende juridisk problemstilling, der analyseres i artiklen som et stabilitets-fleksibilitets dilemma. Kritikken aktualiseres i forhandlingerne af en større h...... handels- og investeringsaftale mellem EU og USA, the Transatlantic Trade and Investment Partnership (TTIP).......Det traktatbaserede regime til beskyttelse af udenlandsk investering har de seneste år været genstand for kritik, der dækker over en grundlæggende juridisk problemstilling, der analyseres i artiklen som et stabilitets-fleksibilitets dilemma. Kritikken aktualiseres i forhandlingerne af en større...
Kan man forandre de sociale problemer i ghettoområder som Vollsmose og Gellerupparken ved at bygge om på husene? Eksempler fra udlandet tyder på, at man kan. I lande som Holland, Frankrig, Spanien, USA og Storbritannien sættes ind over for de sociale problemer i ghettoerne ved at gøre radikalt op...... med boligblok-arkitekturen. Kapitlet om sammenhængen mellem arkitektur og kriminalitet viser at bebyggelsesplanen og bebyggelsesudformning påvirker kriminalitet og utryghed og der gøres rede for de grundlæggende danske erfaringer om hvad der kan gøres for at reducere problemerne, herunder...
Although Lean Manufacturing has been a megatrend for several years, its principles have not been broadly applied in product development processes. We have therefore found it useful to look into the theories of lean manufacturing and to discuss how and to what extent they could be applied in the p......Although Lean Manufacturing has been a megatrend for several years, its principles have not been broadly applied in product development processes. We have therefore found it useful to look into the theories of lean manufacturing and to discuss how and to what extent they could be applied...... in the product development processes, and this study is compared with industrial practices in several front running companies in Denmark. From this research a suggestion for a framework and a tool-box for lean product development is created and discussed from a HR management, an implementation, an operational...
Drotz, Erik; Poksinska, Bozena
The purpose of this paper is to contribute toward a deeper understanding of the new roles, responsibilities, and job characteristics of employees in Lean healthcare organizations. The paper is based on three cases studies of healthcare organizations that are regarded as successful examples of Lean applications in the healthcare context. Data were collected by methods including interviews, observations, and document studies. The implementation of Lean in healthcare settings has had a great influence on the roles, responsibilities, and job characteristics of the employees. The focus has shifted from healthcare professionals, where clinical autonomy and professional skills have been the guarding principles of patient care, to process improvement and teamwork. Different job characteristics may make it difficult to implement certain Lean practices in healthcare. Teamwork and decentralization of authority are examples of Lean practices that could be considered countercultural because of the strong professional culture and uneven power distribution, with doctors as the dominant decision makers. Teamwork, value flow orientation, and company-wide involvement in CI were associated with positive effects on the organizations' working environment, staff development, and organizational performance. In order to succeed with Lean healthcare, it is important to understand and recognize the differences in job characteristics between Lean manufacturing and healthcare. This paper provides insights into how Lean implementation changes the roles, responsibilities, and job characteristics of healthcare staff and the challenges and implications that may follow from this.
M. Shabeena Begam
Full Text Available All manufacturing industry has put in continuous efforts for its survival in the current impulsive and competitive economy. In order to handle the critical situation, manufacturers are trying to implement new and innovative techniques in their manufacturing process by making it more effective and efficient. A detailed literature survey has been conducted to identify the lean practices in various manufacturing industry. The results revealed that the status of Lean Manufacturing (LM implementation in still in thriving stage. This paper will further assist the organizations to improve its process, align it to the requirements of its customers and relentless contribution to manufacturing sector to enhance productivity, quality and competitiveness is immense.
Joosten, Tom; Bongers, Inge; Janssen, Richard
Background Incidents and quality problems are a prime cause why health care leaders are calling to redesign health care delivery. One of the concepts used is lean thinking. Yet, lean often leads to resistance. Also, there is a lack of high quality evidence supporting lean premises. In this paper, we present an overview of lean thinking and its application to health care. Development, theory and application of lean thinking to health care Lean thinking evolved from a tool designed to improve operational shop-floor performance at an automotive manufacturer to a management approach with both operational and sociotechnical aspects. Sociotechnical dynamics have until recently not received much attention. At the same time a balanced approach might lead to a situation where operational and sociotechnial improvements are mutually reinforcing. Application to health care has been limited and focussed mainly on operational aspects using original lean tools. A more integrative approach would be to pay more attention to sociotechnical dynamics of lean implementation efforts. Also, the need to use the original lean tools may be limited, because health care may have different instruments and tools already in use that are in line with lean thinking principles. Discussion We believe lean thinking has the potential to improve health care delivery. At the same time, there are methodological and practical considerations that need to be taken into account. Otherwise, lean implementation will be superficial and fail, adding to existing resistance and making it more difficult to improve health care in the long term. PMID:19696048
Deding, Mette; Holt, Helle
De seneste 10 år har den gennemsnitlige lønforskel mellem kvinder og mænd ligget på ca. 20 pct. I denne antologi stiller SFI skarpt på lønforskellene mellem kvinder og mænd og på de bagvedliggende årsager. Antologien er skrevet af en række fagpersoner, der alle bidrager med en specifik vinkel på ...
Rangaraj, D; Chan, K; Boddu, S; Pawlicki, T; Dieterich, S
Lean thinking has revolutionized the manufacturing industry. Toyota has pioneered and leveraged this aspect of Lean thinking. Application of Lean thinking and Lean Six Sigma techniques into Healthcare and in particular in Radiation Oncology has its merits and challenges. To improve quality, safety and patient satisfaction with available resources or reducing cost in terms of time, staff and resources is demands of today's healthcare. Radiation oncology treatment involves many processes and steps, identifying and removing the non-value added steps in a process can significantly improve the efficiency. Real projects undertaken in radiation oncology department in cutting down the procedure time for MRI guided brachytherapy to 40% less using lean thinking will be narrated. Simple Lean tools and techniques such as Gemba walk, visual control, daily huddles, standard work, value stream mapping, error-proofing, etc. can be applied with existing resources and how that improved the operation in a Radiation Oncology department's two year experience will be discussed. Lean thinking focuses on identifying and solving the root-cause of a problem by asking “Why” and not “Who” and this requires a culture change of no blame. Role of leadership in building lean culture, employee empowerment and trains and develops lean thinkers will be presented. Why Lean initiatives fail and how to implement lean successfully in your clinic will be discussed. Learning Objectives: Concepts of lean management or lean thinking. Lean tools and techniques applied in Radiation Oncology. Implement no blame culture and focus on system and processes. Leadership role in implementing lean culture. Challenges for Lean thinking in healthcare
Rangaraj, D [Baylor Scott and White Health, Temple, TX (United States); Chan, K [Princess Margaret Hospital, Toronto (Canada); Boddu, S [Temple, TX (United States); Pawlicki, T [UC San Diego, La Jolla, CA (United States); Dieterich, S [UC Davis Medical Center, Sacramento, CA (United States)
Lean thinking has revolutionized the manufacturing industry. Toyota has pioneered and leveraged this aspect of Lean thinking. Application of Lean thinking and Lean Six Sigma techniques into Healthcare and in particular in Radiation Oncology has its merits and challenges. To improve quality, safety and patient satisfaction with available resources or reducing cost in terms of time, staff and resources is demands of today's healthcare. Radiation oncology treatment involves many processes and steps, identifying and removing the non-value added steps in a process can significantly improve the efficiency. Real projects undertaken in radiation oncology department in cutting down the procedure time for MRI guided brachytherapy to 40% less using lean thinking will be narrated. Simple Lean tools and techniques such as Gemba walk, visual control, daily huddles, standard work, value stream mapping, error-proofing, etc. can be applied with existing resources and how that improved the operation in a Radiation Oncology department's two year experience will be discussed. Lean thinking focuses on identifying and solving the root-cause of a problem by asking “Why” and not “Who” and this requires a culture change of no blame. Role of leadership in building lean culture, employee empowerment and trains and develops lean thinkers will be presented. Why Lean initiatives fail and how to implement lean successfully in your clinic will be discussed. Learning Objectives: Concepts of lean management or lean thinking. Lean tools and techniques applied in Radiation Oncology. Implement no blame culture and focus on system and processes. Leadership role in implementing lean culture. Challenges for Lean thinking in healthcare.
Mukesh Singh Baghel; Pavan Agrawal
The new systems of doing business in manufacturing have evolved in recent decades Lean production. Lean production can be traced to the 1960s in Japan, when Toyota Motors started innovating changes in mass production to deal with its domestic automotive market. The term “Lean production” was coined around 1989 with the popularity of the book, the machine that can change the world written by researchers at the Massachusetts Institute of Technology (MIT). The term itself was coined ...
April, Joris; Powell, Daryl; Bart, Schanssema
SMEs find it difficult to implement productivity improvement tools, particularly those associated with Lean Manufacturing. Larger companies have more success due to greater access to resources. To provide the SMEs with a way to implement Lean sustainably, the European project ERIP develops a new lean change methodology for SMEs. In this paper the methodology is explained and three test cases show the strength of the methodology. The method is a sequence of achieving management and company sup...
The approach to this paper is to answer the questions such as “how does internal management commitment impact the Lean principles?”, “how does Supply Chain Management practices impact the lean principles?”, “can Supply Chain Management practices be embedded with internal management commitment?
Distelhorst, Greg; Hainmueller, Jens; Locke, Richard M.
This study tests the hypothesis that lean manufacturing improves the social performance of manufacturers in emerging markets. We analyze an intervention by Nike Inc. to promote the adoption of lean manufacturing in its apparel supply chain across eleven developing countries. Using difference-in-differences estimates from a panel of over three hundred factories, we find that lean adoption was associated with a 15 percentage point reduction in noncompliance with labor standards t...
Dondofema, R. A.
Full Text Available South African industry faces immense global competition from developed countries such as Germany probably because of the adoption of lean manufacturing techniques by the latter. This study is a survey on publications concerning implementation and adoption of lean manufacturing in South Africa. To assess South Africa with regards to research publications on lean manufacturing, a benchmark exercise was conducted with Germany for the period 2014 to 2015. The study concludes by highlighting the gaps identified during this survey and recommendations.
Full Text Available The Toyota case proves that lean leadership is of critical importance for the successful implementation and permanent functioning of Lean Production System. There is no ready formula for developing Toyota style lean leadership. However, one may gain inspiration from its experience.
The concept of a Lean Enterprise has proven to be extremely valuable for making companies fit for today's competitive business environment. Lean Information Management denotes the type of information management that is appropriate for such all organization. According to the paradigm of a Lean
Azim Khairi, M.; Rahman, Mohamed Abd
Many academic articles were published in Malaysia promoting the goodness of lean in manufacturing and industrial sectors but less attention was apparently given to the possibility of obtaining the same universal benefits when applying lean in non-manufacturing sectors especially higher education. This study aims to determine the level of lean awareness among a local university’s community taking its Faculty of Engineering (FoE) as the case study. It also seeks to identify typical FoE’s staff perception on lean regarding its benefits and the obstacles in implementing it. A web-based survey using questionnaires was carried out for 215 respondents consisting of academic and administrative staff of the faculty. Statistical Package for the Social Science (SPSS) was used to analyze the survey data collected. A total of 13.95% of respondents returned the forms. Slightly more than half of those responded (56.7%) have encountered some of the lean terms with mean 1.43 and standard deviation 0.504. However, the large amount of standard deviation somewhat indicates that the real level of lean awareness of FoE as a group was low. In terms of lean benefits, reduction of waste was favored (93.3%) by the respondents with mean 0.93 and standard deviation 0.254. For obstacles in implementing lean, lack of knowledge was selected by most respondents (86.7%) to be the major factor with mean 0.87 and standard deviation 0.346. Through the analysis done, the study may conclude that level of lean awareness among the university‘s community was low thus may hinder implementation of lean concept.
Kasivisvanathan, R; Chekairi, A
The concept of 'lean thinking' first originated in the manufacturing industry as a means of improving productivity whilst maintaining quality through eliminating wasteful processes. The purpose of this article is to demonstrate how the principles of 'lean thinking' are relevant to healthcare and the operating theatre, with reference to our own institutional experience.
Full Text Available Lean Six Sigma é uma gestão focada na qualidade e desempenho produtivo em sistemas operacionais. Este artigo discute os fundamentos desta metodologia através de duas diferentes concepções de gestão, Lean Manufacturing e Six Sigma. Primeiro, o artigo explica o DMAIC (definir, medir, analisar, melhorar e controlar e suas respectivas fases, após a filosofia Lean com o sipoc e técnicas de mapeamento de fluxo de valor. O artigo pretende mostrar a integração destes dois conceitos e seus resultados. A metodologia consistiu em uma teoria baseada em uma pesquisa bibliográfica de pesquisa exploratória que consistiu de três estudos de caso em empresas de diferenças localizadas em Sorocaba, São Paulo. Neste artigo estuda a aplicação de Lean Seis Sigma e seus resultados.
V, Vignesh; Suresh, M.; Aramvalarthan, S.
Lean service is an amalgamation of tools and practices which, if applied appropriately, would definitely improve the existing quality of operations and ensure the generation of a large amount of favourable financial and economic outcomes and improve the behaviour of the workforce. As a result, it assumes of great significance in the fiercely competitive modern world. This article presents a comprehensive bibliographic study about the various lean service practices through a variety of approaches like service improvement, manufacturing, supply chain, market and retailing approaches, etc. Thus it gives a clear view on how the lean services are implemented in various sectors and the contribution of lean service towards improving the quality in the services provided while reducing the costs.
Rüttimann, Bruno G.; Fischer, Urs P.; Stöckli, Martin T.
Lean Six Sigma tools have been increasingly employed also in the service industry, however with different success as field studies have shown. The reason not only has to be attributed to a poor Change Management, but can also be attributed to the intrinsic characteristics of the Lean techniques, which have been tailored to sustain a stable customer-takted pull-manufacturing principle. An office workplace shows significant differences to a procedural shop floor environment, as it comprises bot...
Zee, van der J.T.M.; Blijleven, V.B; Gong, Y.
Lean, as a philosophy, has been around for quite some time, predominantly in the manufacturing domain. Since the 1990s Lean management provides organizations with a way to achieve superior performance by focusing on customer value, innovation and productivity. In 2011 Steven Bell and Michael Orzen
Ana Paula Barth Bartz
, increasing their efficiency. The objective of this study was to decrease the lead-time required by the studied company, by practical application of just-in-time searching for lean production in a metalworking company, manufacturer of agricultural implements. To meet this purpose, a case study of qualitative and descriptive order was carried out. To collect data, observation and documental analysis were performed, in order to understand the production processes, then working with the collection of data, through structured interviews in order to identify the difficulties encountered by suppliers in providing the supplies within the agreed specifications. The company had high indexes of late delivery of their products because of the high lead-time. Through the development of the mapping of actual flow, it was found that the organization was working with a production pushed and much of the late occurred because of problems in the supply of inputs. By eliminating tasks that did not add value to the final product, a lean value flow was produced for the process, identifying the major problems which caused the suppliers to provide the supplies out of specification or out of date and suggested actions that could be implemented for the elimination of these delays. Through these actions, the reduction in lead time was observed, helping to better meet delivery deadlines, increased competitiveness, a relevant fact to keep in today's market of agricultural equipment.
Slomp, J.; Bokhorst, J.A.C.; Germs, R.
Due to the success of lean manufacturing, many companies are interested in implementing a lean production control system. Lean production control principles include the levelling of production, the use of pull mechanisms and takt time control. These principles have mainly been applied in high volume
This book covers recent research and trends in Manufacturing Engineering. The chapters emphasize different aspects of the transformation from materials to products. It provides the reader with fundamental materials treatments and the integration of processes. Concepts such as green and lean manufacturing are also covered in this book.
Powell, D.; Riezebos, J.; Strandhagen, J.O.
It is generally accepted that lean production improves manufacturing processes through the systematic application of lean practices, and equally assumed that present day IT systems, particularly ERP systems, are essential for companies seeking efficiency through organisational integration. Though
de Jong, Stephan J.; Beelaerts van Blokland, W.W.A.
Purpose – Implementation of lean manufacturing is currently performed in the production industry; however, for the airline maintenance service industry, it is still in its infancy. Indicators such as work in process, cycle time, on-time performance and inventory are useful indicators to measure
Ahmad Ahmad Nur Aizat
Full Text Available In recent years, lean manufacturing is being followed by various sectors in order to keep their competitiveness in the global markets. Lean manufacturing plays a vital role in improving the efficiency of operation by eliminating or reducing wastes. Nonetheless, most of small and medium enterprises (SMEs lack sufficient knowledge or information on the benefits of implementing lean manufacturing. The main objective of this study is to apply value stream mapping, one of lean manufacturing tools, for improving the productivity in a SME by eliminating non-value added activities. In this study, lean manufacturing was adopted at a SME, particularly a food industry. Value stream mapping was served as main tool to identify the wastes and improvement opportunities in production line. Subsequently, different lean manufacturing tools such as Kaizen Burst, one piece flow, and 5S were applied to eliminate or reduce identified wastes. Based on the future state value stream mapping, final results showed that the total operation time and non-added value activities time were successfully decreased from 1993 seconds to 1719 seconds, and 234 seconds to 104 seconds, respectively. The findings of this study indicate that value stream mapping is an effective approach to eliminate the wastes and improve the productivity.
Lean is a comprehensive system of management based on the Toyota production system (TPS), encompassing all the activities of an organization. It focuses management activity on creating value for the end-user by continuously improving operational effectiveness and removing waste. Lean management creates a culture of continuous quality improvement with a strong emphasis on developing the problem-solving capability of staff using the scientific method (Deming's Plan, Do, Check, Act cycle). Lean management systems have been adopted by a number of histopathology departments throughout the world to simultaneously improve quality (reducing errors and shortening turnround times) and lower costs (by increasing efficiency). This article describes the key concepts that make up a lean management system, and how these concepts have been adapted from manufacturing industry and applied to histopathology using a case study of lean implementation and evidence from the literature. It discusses the benefits, limitations, and pitfalls encountered when implementing lean management systems.
Srinivasa Rao, P.; Niraj, Malay
Lean manufacturing concept is becoming a very important strategy for both academicians and practitioners in the recent times, and Japanese are using this practice for more than a decade. In this present scenario, this paper describes an innovative approach for lean performance evaluation by using fuzzy membership functions before and after implementing lean manufacturing techniques and formulating a model to establish the lean score through the lean attributes by eliminating major losses. It shows a systematic lean performance measurement by producing a final integrated unit less-score.
P. Marksberry; S. Hughes
Lean manufacturing (Lean), as evolved from the Toyota Production System (TPS), has gained traction in many businesses as a tool for efficiency and improvement. However, the role of an executive or general manager within a Lean organization has not been clearly articulated in any official or proven way. This research looks at common approaches, theories, and problems concerning the role of the executive and how it can affect companies in their efforts to adopt Lean tools and principles. This r...
Toussaint, John S; Berry, Leonard L
An urgent need in American health care is improving quality and efficiency while controlling costs. One promising management approach implemented by some leading health care institutions is Lean, a quality improvement philosophy and set of principles originated by the Toyota Motor Company. Health care cases reveal that Lean is as applicable in complex knowledge work as it is in assembly-line manufacturing. When well executed, Lean transforms how an organization works and creates an insatiable quest for improvement. In this article, we define Lean and present 6 principles that constitute the essential dynamic of Lean management: attitude of continuous improvement, value creation, unity of purpose, respect for front-line workers, visual tracking, and flexible regimentation. Health care case studies illustrate each principle. The goal of this article is to provide a template for health care leaders to use in considering the implementation of the Lean management system or in assessing the current state of implementation in their organizations. Copyright © 2013 Mayo Foundation for Medical Education and Research. Published by Elsevier Inc. All rights reserved.
Kristensen, Thomas Borup; Israelsen, Poul
To understand how the practices of Lean affect performance, we tested and validated a system-wide approach using mediating relationships in a structural equation model. We used a cross-sectional survey of 200 Danish companies that indicated that they used Lean. Thus, this study is especially...... relevant to Denmark, but the approach is empirically more generalizable. We show that the effect of Lean standardized flow production practices on performance is mediated by analytical continuous improvement empowerment practices and by delegation of decision rights practices. Thus, standardized flow...... of decision rights. The paper provides evidence that supports the view that middle managers’ actions further enhance performance in Lean companies. The right Lean behavior by middle managers increases the level of analytical continuous improvement empowerment. In total, high-performing Lean companies...
Full Text Available Purpose: Since the emergence of Lean Manufacturing many organizations strived to implement it. Nonetheless, sustainable Lean transformation is not as easy as to be simply achieved. Several aspects need to be taken into account before Lean implementation which national and organizational culture are important. By considering influences of national culture on the organizational culture, this paper aims at proposing an evaluation model to determine the cultural weaknesses of an organization and give some recommendations to manage people before implementing Lean. Design/methodology/approach: This research has been conducted based on literature review survey and semi-structured interviews. Research papers, conference proceedings, books, and official websites regarding Lean philosophy were reviewed to find the influence of national culture in Lean implementation. Different databases were scrutinized, from 2015 to 2017, containing Scopus and Web of Science with the time period of 1996-2016. A set of key terms and their combinations were used including: Toyota Production system, Lean production, Lean manufacturing, Lean management, Transformation, Implementation, Barriers/ Impediments/Challenges/Difficulties, Human resources, Success factors, Organizational culture, and National culture. Findings: The proposed evaluation model is a guide for organizations to determine cultural misalignments between the corporate culture and the Lean culture before its implementation and gives some managerial recommendations to correct them. Originality/value: This study is the first attempt to integrate the national models with Lean culture to provide an evaluation model and some recommendations to help the organization to align its culture to Lean culture before its implementation.
for filialsammenlægningens skatteretlige virkningstidspunkt i Danmark. (6) Det gør ingen forskel for dette facit, om fusionsregnskabet følger årsregnskabsloven, IAS eller IFRS. Mellem årsregnskabsloven og selskabslovgivningen har sidstnævnte forrang. Mellem IAS/IFRS og selskabslovgivningen har førstnævnte forrang, men kun...
Fit, slankere, hurtigst. Lean-konceptet ruller ind over de offentlige institutioner, hvor det skal trimme og effektivisere arbejdsprocesser. Men hvor er den maksimale grænse for effektivitet? Er der et ’tipping point’, hvor Lean ikke længere motiverer, men snarere udmatter......Fit, slankere, hurtigst. Lean-konceptet ruller ind over de offentlige institutioner, hvor det skal trimme og effektivisere arbejdsprocesser. Men hvor er den maksimale grænse for effektivitet? Er der et ’tipping point’, hvor Lean ikke længere motiverer, men snarere udmatter...
Globalisering og migration har forøget mamgfoldighed og uligheder inden for og mellem nationerne og har skabt nye problemer for offentlige politikker og nye behov for at regulere politiske og socio-økonomiske problemer nationalt og globalt. Artiklen behandler disse udfordringer med særlig fokus på samspillet mellem køn og mangfoldighed. Det dobbelte formål er først at nyvurdere begreber om medborgerskab, nationalitet og tilhørsforhold i lyset af lokale og globale relationer og multikulturalis...
Full Text Available Originally developed to improve the quality and production efficiency, Lean Six Sigma is now widely adopted in other non-manufacturing sectors such as financial, trade, services, etc. The methodology known as Lean Six Sigma combines the Six Sigma techniques, ‒ which allow companies to reduce manufacturing defects ‒ and the Lean Manufacturing principles, ‒ which help companies benefit from faster processing for lower costs and with superior quality. As a result of the research, the authors observed that, despite growing popularity and impressive outcomes obtained by some companies, the Lean Six Sigma model does not always offer the expected results. However, the research has shown that the analysed company, operating in the field of courier services has managed to boost productivity and competitiveness by implementing measures that generated added value.
Full Text Available This article is intended to using of Six Sigma methodology. A break trough strategy to significantly improve customer satisfaction and shareholder value by reducing variability in every aspects of business. It enhances the ability to delivery customer satisfaction and cost improvement results faster – within months from the start, and sustains the rate of improvement on-going. One of the most powerful ways to improve business performance is combining business process management (BPM strategies with Six Sigma strategies. BPM strategies emphasize process improvements and automation to drive performance, while Six Sigma uses statistical analysis to drive quality improvements. The two strategies are not mutually exclusive, however, and some savvy companies have discovered that combining BPM and Six Sigma can create dramatic results. Six Sigma methodology teaches and deploys hard skills and business practices emphasizing.
Full Text Available The paper is dedicated to answer the problem of measuring waste in companies, which are implementing Lean Manufacturing concept. Lack of complex identification, quantification an visualization of waste significantly impedes Lean transformation efforts. This problem can be solved by a careful investigation of Muda, Muri and Mura, which represent the essence of waste in the Toyota Production System. Measuring them facilitates complete and permanent elimination of waste in processes. The paper introduces a suggestion of methodology, which should enable company to quantify and visualize waste at a shop floor level.
Binner, Hartmut F.
INHALT: l. Einleitung und Standortbestimmung 2. Japanische Wertvorstellungen 3. Inhalte der Lean Production 4. Fertigungssegmentierung 5. Informationsmanagement mit CIM- und Logistik-Komponenten 6. Logistikgerechte Strukturen der Lean Production 7. Realisierung der Lean Production 8. Zusammenfassung
The Lean and Information Technology Toolkit is a how-to guide which provides resources to environmental agencies to help them use Lean Startup, Lean process improvement, and Agile tools to streamline and automate processes.
Sethi, Rajiv; Yanamadala, Vijay; Burton, Douglas C; Bess, Robert Shay
Lean methodology was developed in the manufacturing industry to increase output and decrease costs. These labor organization methods have become the mainstay of major manufacturing companies worldwide. Lean methods involve continuous process improvement through the systematic elimination of waste, prevention of mistakes, and empowerment of workers to make changes. Because of the profit and productivity gains made in the manufacturing arena using lean methods, several healthcare organizations have adopted lean methodologies for patient care. Lean methods have now been implemented in many areas of health care. In orthopaedic surgery, lean methods have been applied to reduce complication rates and create a culture of continuous improvement. A step-by-step guide based on our experience can help surgeons use lean methods in practice. Surgeons and hospital centers well versed in lean methodology will be poised to reduce complications, improve patient outcomes, and optimize cost/benefit ratios for patient care.
Lean Thinking is currently often positioned as the underlying theory of lean production among practitioners and academics, although its originators, Womack and Jones, seem not to have presented it as a theory. This paper endeavors to analyze whether Lean Thinking can be viewed as a theory of lean production. For this purpose, a critical assessment of Lean Thinking is carried out. Lean Thinking is argued to lack an adequate conceptualization of production, which has led to imprecise concepts, ...
Wallace, Guy W.
Explains lean instructional systems design/development (ISD) as it relates to curriculum architecture design, based on Japan's lean production system. Discusses performance-based systems; ISD models; processes for organizational training and development; curriculum architecture to support job performance; and modular curriculum development. (LRW)
The paper reports on findings from the initial, exploratory phase of a longitudinal research study aimed at developing a framework for implementing lean while ensuring employee well-being. Data from observations and in-depth dialogues with persons involved in lean implementation, along...
Olga Maria Formigoni Carvalho Walter
Full Text Available Apesar da ampla literatura existente sobre Manufatura Enxuta (ME, pouco esforço tem sido dedicado a sintetizar o estado da arte sobre métodos que avaliam sua implantação. Nesse sentido, este artigo tem como objetivo apresentar uma revisão da literatura sobre métodos científicos de avaliação da implantação da ME, buscando identificar suas principais características. Foram identificados 48 artigos relacionados ao tema, no período de 1996 a agosto de 2012. Depois da revisão, as publicações foram classificadas, utilizando os seguintes parâmetros de caracterização: tipo de abordagem metodológica; foco de avaliação; forma de apresentação do diagnóstico; dinâmica de aplicação do diagnóstico de avaliação; práticas clássicas da ME avaliadas; entre outros parâmetros complementares. A principal contribuição desta pesquisa concentra-se em condensar em um único material, uma visão geral sobre os métodos de avaliação da ME para que pesquisadores e profissionais da área selecionem o método que melhor se adapte à realidade de determinada empresa, ou o que ofereça a melhor perspectiva de como se apresenta a implantação da ME.Despite the extensive literature on Lean Manufacturing (LM, little effort has been made to synthetize the state-of-the-art methods used to assess LM implementation. Accordingly, this article aims to present a literature review on scientific assessment methods for LM to identify their main characteristics. Forty eight articles related to the topic published between 1996 and August 2012 were identified. These publications were then classified using the following characterization parameters: methodological approach, assessment focus, diagnostic process procedure; diagnostic assessment dynamics; and classic LM practices assessed among other complementary parameters. The main contribution of this research is to provide researchers and management professionals with a compiled account of LM assessment
, baseret på det klassiske weberske bureaukratis forestillinger om lederrollen og organisering. Profesioners konflikt med 'ledelse og Djøfisering' er således i høj grad en rivalisering mellem ligeværdige logikker og fagligheder og ikke blot en kamp mod en uforstående overmagt. En 'professionsgørelse' af...
Edwards, Kasper; Møller, Niels; Kristensen, Tage Søndergård
ledelsessystem, KPI’er og bonussystemet. Det er alene resultaterne der tæller. Til trods for dette pres, viser projektet at der er betydelig variation i psykisk arbejdsmiljø mellem centrene som korrelerer med rentabilitet. Forløbsanalyserne viser ikke entydigt, om godt psykisk arbejdsmiljø er årsagen til høj...
Aij, Kjeld Harald; Teunissen, Maurits
Purpose Emphasis on quality and reducing costs has led many health-care organizations to reconfigure their management, process, and quality control infrastructures. Many are lean, a management philosophy with roots in manufacturing industries that emphasizes elimination of waste. Successful lean implementation requires systemic change and strong leadership. Despite the importance of leadership to successful lean implementation, few researchers have probed the question of ideal leadership attributes to achieve lean thinking in health care. The purpose of this paper is to provide insight into applicable attributes for lean leaders in health care. Design/methodology/approach The authors systematically reviewed the literature on principles of leadership and, using Dombrowski and Mielke's (2013) conceptual model of lean leadership, developed a parallel theoretical model for lean leadership in health care. Findings This work contributes to the development of a new framework for describing leadership attributes within lean management of health care. Originality/value The summary of attributes can provide a model for health-care leaders to apply lean in their organizations.
Full Text Available Purpose: The purpose of this study is to examine the characteristic of the lean principles into ISO 14001 and to propose linkage of the lean principles and ISO 14001.Design/methodology/approach: To achieve the objective of the study, literature survey and quantitative research method using questionnaires survey are used.Findings and Originality/value: The findings of this study confirm that ISO 14001 certified company adopted lean production practices. The study also proves that lean principles have positive and significant relationship with ISO 14001 EMS and the linkage can be made between lean principles and ISO 14001 to achieve Continual Improvement.Research limitations/implications: The small sizes of the sample of the participating companies are the main limitations of this study and this research mainly focuses on the manufacturing environment and services industry.Practical implications: This research show that all ISO 14001 companies do adopt at least one lean production practices and the main findings are lean principles has positive and highly significant relationship with ISO 14001 requirements. This is because the integration of lean principles into ISO 14001 will serve practical methods for ISO14001 EMS to achieve the continual improvement.Originality/value: This research is amongst the first to study the combined lean principles with ISO 1400. Based on the current situation, there is no integration within this two management system.
Brännmark, Mikael; Holden, Richard J
Lean Production is a dominant approach in Swedish and global manufacturing and service industries. Studies of Lean's employee effects are few and contradictory. Employee effects from Lean are likely not uniform. This paper investigates the effect of employees' participation on their experiences of Lean. This study investigated how different packages of employee participation in Lean affected manufacturing workers' experiences of Lean. During 2008-2011, qualitative and quantitative data were collected from Swedish manufacturing companies participating in the national Swedish Lean Production program Produktionslyftet. Data from 129 surveys (28 companies), 39 semi-structured interviews, and 30 reports were analyzed. In the main analysis, comparisons were made of the survey-reported Lean experiences of employees in three groups: temporary group employees (N = 36), who participated in Lean mostly through intermittent projects; continuous group employees (N = 69), who participated through standing improvement groups; and combined group employees (N = 24), who participated in both ways. Continuous group employees had the most positive experience of Lean, followed by the combined group. Temporary group employees had the least positive experiences, being less likely than their counterparts to report that Lean improved teamwork, occupational safety, and change-related learning, decision making, and authority. These findings support the importance of continuous, structured opportunities for participation but raise the possibility that more participation may result in greater workload and role overload, mitigating some benefits of employee involvement. Consequently, companies should consider involving employees in change efforts but should attend to the specific design of participation activities.
van der Zee, D.J.; Pool, A.; Wijngaard, J.; Mason, S.J.; Hill, R.R.; Moench, L.; Rose, O.
Lean manufacturing aims at flexible and efficient manufacturing systems by reducing waste in all forms, such as, production of defective parts, excess inventory, unnecessary processing steps, and unnecessary movements of people or materials. Recent research stresses the need to include planning
Full Text Available Under the current economic conditions many organizations strive to continue the trend towards adopting better software development processes, in order to take advantage of the numerous benefits that these can offer. Those benefits include quicker return on investment, better software quality, and higher customer satisfaction. To date, however, there is little body of research that can guide organizations in adopting modern software development practices, especially when it comes to Lean thinking and principles. To address this situation, the current paper identifies and structures the main wastes (or muda in Lean terms in software development as described by Lean principles, in an attempt to bring into researchers’ and practitioners’ attention Lean Software Development, a modern development methodology based on well-established practices such as Lean Manufacturing or Toyota Production System.
The methods of lean manufacturing primarily designed for businesses dealing with serial production, are also used in other types of production. However the concept of lean production was not designed for these types of businesses, they are utilized only partially. Paper focuses on applying methods of lean concept in companies which are dealing with mass production and their options of exchange for other methods in the event of disagreement. Basis of the article is a list of lean methods with its description and its utilization in practice. The questionnaire was utilized to identify information from the practice. Based on this survey were identified the critical methods that are no longer appropriate for companies dealing with mass production. However, there are alternative methods of describing the problem. It is possible to say that companies are trying to get closer to their goal by modification of the basic concepts. And the concept of Lean Enterprise serves as a standard.
Iuga Maria Virginia
Full Text Available As global market competition is getting fiercer, and companies are looking at ways to stay on top, more and more organizations are looking at Lean Manufacturing and lean tools to support them in achieving their goals. Especially within the automotive industry, lean practices are very well received. The speed at which the automotive industry is evolving, especially but not only, in countries like Romania, leads to the need to carefully analyze lean manufacturing concepts, examine them against local production conditions, and to develop and standardize them. One of the most important things to take into consideration here is the application of an adequate problem solving technique to avoid waste. The objective of this research paper lies in analyzing and comparing the problem-solving methods recommended by the Toyota Production System, and to propose their appropriate application at shop floor, in relation to the specific problem type.
Shields, John T
... using a philosophy called "lean." LAl's mission is to research, develop, and promulgate practices, tools, and knowledge that enable and accelerate the envisioned transformation of the greater US aerospace enterprise through people and processes...
Full Text Available Invalid organisation of the production environment in an enterprise is the cause of many disruptions during the implementation of production processes. Lean Management is aimed at improving processes and eliminating interference in accordance with the Kaizen principle. A significant element of management constantly analyses and measures the improved results. The article presents the results of the literature research from the scope of observation methods and measuring the effects of the use of Lean Management instruments in manufacturing companies.
Full Text Available Lean manufacturing is widely considered to be a proven organisational improvement philosophy, yet the success rate of lean implementation in industry remains relatively low. Neglect of the human aspect of lean manufacturing is often cited as the leading reason for this, despite the emphasis so clearly placed upon this aspect by the creators of the lean philosophy. This article reviews the extent to which the human dimensions of the lean philosophy, as described in the Toyota Way management principles, have been incorporated in lean implementation strategies. It is found that few of the principles feature prominently in these strategies. Notably absent are those linked to the ‘respect for people’ pillar , which forms half of the T oyota Way’s foundation. This conclusion indicates that the adoption of the lean philosophy runs contrary to the oft-repeated message from its creators that no tenet of the philosophy should be favoured at the expense of another. This may provide valuable insight into the reasons for the high implementation failure rate.
Daniel D. GEORGESCU
Full Text Available Productivity growth is a fundamental means for society to improve its living standards. Productivity growth comes from technological change (new ways of producing goods and services and better organisation of production (better ways of using available resources given available technology. Both processes operate simultaneously and, in practice, it is difficult to distinguish between the effects of each process. The processes are dynamic and affect individual activities differently over time. These years, manufacturing functions have been transferred rapidly and globally from mature countries to emerging countries. This paper is about the lean philosophy and the critical elements for successful transfer of lean management among sites and countries.
Full Text Available LEAN thinking and Six Sigma have been utilized by manufacturing industries to decrease cost and improve quality and productivity by reducing variation and production defects . Because of the dramatic successes in manufacturing, there is rising interest among companies in the pharmaceutical industry, which chooses to implement LEAN in order to accomplish such goals as decreased wait time to release product to the market, reduce production waste, and improve communication with end users and raize quality level both in the production and in testing laboratories. In this article, basics of LEAN and Six Sigma are presented and suggestion was given for application of their concepts in pharmaceutical industry together with harmonization with legal regulation represented by requirements Good Manufacturing Practice (cGMP, in order to work "smarter", more cost-effectively and avoid was ting time and other resources.
Full Text Available LEAN thinking and Six Sigma have been utilized by manufacturing industries to decrease cost and improve quality and productivity by reducing variation and production defects. Because of the dramatic successes in manufacturing, there is rising interest among companies in the pharmaceutical industry, which choose to implement LEAN in order to accomplish such goals as decreased wait time to release product to the market, reduce production waste, improve communication with end users and raise quality level both in the production and in testing laboratories. In this article, basics of LEAN and Six Sigma are presented and suggestion was given for application of their concepts in pharmaceutical industry together with harmonization with legal regulation represented by requirements Good Manufacturing Practice (cGMP, in order to work "smarter", more cost- effectively and avoid wasting time and other resources.
Bligaard, H B; Petersen, M B; Trinderup, M
Der er mange bud på sammenhæng mellem fodringen og gødningskonsistensen base-ret på praktiske erfaringer. Blandt andet tyder erfaringerne på, at mere græs og et højt proteinindhold kan give en mere tynd gødning, hvorimod fodring med majs- og helsædsensilage kan give en mere fast gødning. Formålet...
Full Text Available Jeg vil i denne artikel præsentere gestalttilgangens teoretiske og praktiske grundstruktur. Der vil endvidere blive redegjort for, hvordan gestalttilgangens feltteori, med inspiration fra Ken Wilber’s integrale perspektivisme (Wilber 1995; 2000; 2006, kan danne grundlag for en integrativ rammesætning for forskellige psykologiske og psykoterapeutiske tilgange, samt for en forståelse af forholdet mellem terapi og coaching.
Full Text Available All Original Equipment Manufacturers (OEM organizations in Aerospace, Automotive and Electronics industries had to upgrade their functions. These organizations including suppliers and solutions providers are duty bound to improve their functions through strategic initiatives. One such initiative is Lean Process Management. Lean Process Management has proven to aid organizations in developing manufacturing and administrative management solutions and make the organization a leaner at the same time a ‘fitter’ one, achieving World Class standards in terms of production, quality, marketing, etc, etc. The issue or problem is, although a number of authors, experts, researchers have discussed the lean process management as part organization centric issues, they failed to provide an effective lean process management system. Besides the need to formulate an effective lean process as suggested by some authors, another important reason suggested is the employee’s development aspect regarding how to unlock the infinite potential of their workforce. This employee’s development is basically the problem solving capabilities of the employees while implementing the Lean through clear cutting protocols or processes of Lean Process Management. The employees need to be developed and equipped to contribute optimally to the process. Because of this scenario, the main objective of this study is to develop an employees development system which the author has acronym or trademark it as People Development System (PDS to enhance problem solving capability among its employees while implementing the lean process management there. Although, the PDS can be implemented throughout the organization, if it is implemented in a particular department in an organization, it will be feasible to study and analyze its effectiveness in-depth. So, this study documents and analyzes the implementation of Lean process in the Kitting Department of the aerospace company, ABC Company
This Lean Replication Primer describes how EPA Offices and Regions can identify and adapt successful practices from previous Lean projects to “replicate” their successes and generate further improvements.
Doreswamy, Rajiv; Self, Timothy A.
The Ares launch vehicles team, managed by the Ares Projects Office (APO) at NASA Marshall Space Flight Center, has completed the Ares I Crew Launch Vehicle System Requirements Review and System Definition Review and early design work for the Ares V Cargo Launch Vehicle. This paper provides examples of how Lean Manufacturing, Kaizen events, and Six Sigma practices are helping APO deliver a new space transportation capability on time and within budget, while still meeting stringent technical requirements. For example, Lean philosophies have been applied to numerous process definition efforts and existing process improvement activities, including the Ares I-X test flight Certificate of Flight Readiness (CoFR) process, risk management process, and review board organization and processes. Ares executives learned Lean practices firsthand, making the team "smart buyers" during proposal reviews and instilling the team with a sense of what is meant by "value-added" activities. Since the goal of the APO is to field launch vehicles at a reasonable cost and on an ambitious schedule, adopting Lean philosophies and practices will be crucial to the Ares Project's long-term SUCCESS.
Seddon, John; O'Donovan, Brendan; Zokaei, Keivan
Ever since Levitt's influential Harvard Business Review article 'Production-Line Approach to Service' was published in 1972, it has been common for services to be treated like production lines in both the academic literature and more widely in management practice. The belief that achieving economies of scale will reduce unit costs is a common feature of management decision-making. As technological advancement has produced ever more sophisticated IT and telephony, it has become increasingly easier for firms to standardise and off-shore services. The development of the 'lean' literature has only helped to emphasise the same underlying management assumptions: by managing cost and workers' activity, organisational performance is expected to improve. This chapter argues that through misinterpretation of the core paradigm 'lean' has become subsumed into the 'business as usual' of conventional service management. As a result, 'lean' has become synonymous with 'process efficiency' and the opportunity for significant performance improvement - as exemplified by Toyota - has been missed.
Background To be more efficient, reduce costs but still maintain or actually raise the quality, is the content of an ordinary workday in organizations nowadays – also in the public sector and service industry. To deal with those demands and needs, organizations often implement different improvement systems, like Lean. Lean with its origins in car manufacturing is today used widely for improvement, also in public sector and service industry. Womack and Jones states that Lean is built by five p...
Full Text Available Lean Management is a philosophy and management concept, based on reduction of the waste and resources used in the process of producing goods and providing services. Lean Management genesis dates back to scientific management in America (for example concepts of H. Ford and F.W. Taylor and quality management, including development of TQM concept. Japanese Toyota Production System has been inspired by chosen elements of these concepts, and then it evolved towards global concept called Toyota Way (which connects production rules with values and work attitude.
Nielsen, Anders Paarup; Edwards, Kasper
The ideas and principles from lean management are now widely being adopted within the healthcare sector. The analysis in this paper shows that organizations within healthcare most often only implement a limited set of tools and methods from the lean tool-box. Departing from a theoretical analysis...... of the well-known and universal lean management principles in the context of the healthcare this paper will attempt to formulate and test four hypotheses about possible barriers to the successful implementation of lean management in healthcare. The first hypothesis states that lean management in healthcare....... The paper concludes by discussing the implications of hypothesis two, three, and four for the successful application of lean management within healthcare. Is it concluded that this requires a transformative and contingent approach to lean management where the universal principles of the lean philosophy...
The Lean in Air Permitting Guide is designed to help air program managers at public agencies better understand the potential value and results that can be achieved by applying Lean improvement methods to air permitting processes.
This Lean and Environment Toolkit assembles practical experience collected by the U.S. Environmental Protection Agency (EPA) and partner companies and organizations that have experience with coordinating Lean implementation and environmental management.
Aij, K.H.; Visse, M.A.; Widdershoven, G.A.M.
Purpose – The purpose of this study is to provide a critical analysis of contemporary Lean leadership in the context of a healthcare practice. The Lean leadership model supports professionals with a leading rolein implementing Lean.This article presents a case study focusing specifcally on
Da Silva Vieira, S.L.
This doctoral thesis proposes ways for the translation of the Lean Thinking (LT) into design practice and research, taking the LT concepts as dimensions to study designers’ behavior across design disciplines. Lean Thinking has its roots in manufacturing, however, as a philosophy of guiding
The purpose of this study was to investigate whether or not there have been successful applications of lean manufacturing principles in highly variable defense IT environments. Specifically, the study assessed if implementation of the lean philosophies by a defense organization yielded repeatable, predictable results in software release schedules…
Overboom, M.A.; Small, J.S.; Naus, A.J.A.M.; de Haan, J.A.C.
The article offers information on the application of lean principles to achieve continuous flow in third party logistics providers (3PLs). It mentions that lean management principles and practices have been traditionally applied to manufacturing systems and try to make products flow through the
Bravos, Cynthia; Adler, Isabel K.
This paper aims at presenting how a Brazilian innovation consultancy guided a collaborative development of a mobile solution using the Design Thinking approach (Vianna et al, 2012) and Lean principles (Ries, 2011). It will describe tools and methods used and how it was applied to requirement gath...
Hasle, Peter; Bojesen, Anders; Jensen, Per Langaa
for the negative impact of lean on both the working environment and employee health and well-being in cases of manual work with low complexity. However, since examples of positive effects were also found in the literature, it is important to move from a simple cause-and-effect model to a more comprehensive model...... of manufacturing industry. The literature reflects, only to a limited extent, on the significance of implementation strategy and production context. Practical implications - Organizations working with lean should make efforts to avoid an impaired working environment for manual employees. Involvement of employees......Purpose - The effects of lean on employees have been debated ever since the concept was introduced. The purpose of this paper is to review the scientific literature on the effects of lean on the working environment and employee health and well-being. Design/methodology/approach - Relevant databases...
Full Text Available Lean principles and techniques can be successfully applied in the retail sector. In the retail sector, lean approach improves operational flows. Lean retail encourages manufacturers to produce standard products in accordance with the created (placed orders from retailers pursuant to the demand of their consumers. Characteristics of the retail market are: strong competition, shorter product life cycle, longer product development time and high sensitivity of demand. In order to be more competitive and profitable today's retailers operate strategically oriented to lower prices and gain exemption from holding unnecessary stocks. Lean retail is an example of best practices of successful operational strategies which management need to accept - to maximize the operating efficiency of the retail process.
Hwang, Pauline; Hwang, David; Hong, Paul
Increasingly, healthcare providers are implementing lean practices to achieve quality results. Implementing lean healthcare practices is unique compared to manufacturing and other service industries. The purpose of this paper is to present a model that identifies and defines the lean implementation key success factors in healthcare organisations. The model is based on an extant literature review and a case illustration that explores actual lean implementation in a major USA hospital located in a Midwestern city (approximately 300,000 people). An exploratory/descriptive study using observation and follow-up interviews was conducted to identify lean practices in the hospital. Lean practice key drivers include growing elderly populations, rising medical expenses, decreasing insurance coverage and decreasing management support. Effectively implementing lean practices to increase bottom-line results and improve organisational integrity requires sharing goals and processes among healthcare managers and professionals. An illustration explains the model and the study provides a sound foundation for empirical work. Practical implications are included. Lean practices minimise waste and unnecessary hospital stays while simultaneously enhancing customer values and deploying resources in supply systems. Leadership requires clear project targets based on sound front-end planning because initial implementation steps involve uncertainty and ambiguity (i.e. fuzzy front-end planning). Since top management support is crucial for implementing lean practices successfully, a heavyweight manager, who communicates well both with top managers and project team members, is an important success factor when implementing lean practices. Increasingly, green orientation and sustainability initiatives are phrases that replaced lean practices. Effective results; e.g. waste reduction, employee satisfaction and customer values are applicable to bigger competitive challenges arising both in specific
Fourie, C. J.
Full Text Available Historically, Lean thinking has limited applications in the maintenance environment (that is, a non-manufacturing environment. This article reports on the Lean tools that can be implemented in the maintenance environment. To achieve this, a typical supply chain management of a rolling stock service organisation was used for analysis and validation. The approach was initially to map the current supply chain process through a standard method of value stream mapping so as to identify non-Lean activities. After mapping the current state, other suitable Lean tools for the current supply chain management were applied. Finally, performance Indicators were formulated for continuous review and assessment.
Lean management is a philosophy focused on identifying and eliminating waste throughout a product’s entire value stream. It originates from the manufacturing system of Japanese automotive manufacturer Toyota and attracted due to its tremendous success widespread attention worldwide. Lean promises significant benefits in terms of waste reduction, and increased organizational and supply chain communication and integration.Generally, in terms of operations and improvements service companies are ...
Houshmand & Jamshidnezhad (2006) proposed a hierarchical structure to ... mentation of leanness in an organization but no such assessment system ... (v) Motion (walking or moving of people or equipment more than what is ..... software simulation based intelligent manufacturing system for a pilot CIM facility that could.
Edwards, Kasper; Nielsen, Anders Paarup; Jacobsen, Peter
The principles of lean production originating from the Toyota production system has spread from manufacturing to healthcare. Needless to say, this raises concern whether such principles are actually applicable where the product are humans in need of medical care and what are the consequences...
Rasmussen, Erik Stavnsager; Tanev, Stoyan
The risk of launching new products and starting new firms is known to be extremely high. The Lean Start-up approach is a way of reducing these risks and enhancing the chances for success by validating the products and services in the market with customers before launching it in full scale. The ma...... and the final business model. In other words: The start-up must first nail the problem together with the customers, then develop the solution and test, and then in the end scale it to a full-grown business model.......The risk of launching new products and starting new firms is known to be extremely high. The Lean Start-up approach is a way of reducing these risks and enhancing the chances for success by validating the products and services in the market with customers before launching it in full scale. The main...
This book focusses on the challenges and changes organizational management faces in an era when the need to develop environmentally aware processes meets high levels of competition. It covers the synergetic effects, how re-use, recycling, waste reduction, and other sustainable production strategies can add value, low costs and time of production. Sustainable business behavior is not only an environmental perspective on management, but more and more contains an organizational perspective. Taking into account these issues, green and lean management appears as the way managers can drive their employees to continuously improve the management processes that add value to the organization and costumers. This book provides information on principles, strategies, models, and applications of green and lean management, and at the same time communicates the latest research activity relating to this scientific field world-wide.
Dr. Revathi Iyer
Full Text Available Great organizations have become leaders due to their leadership and sustainable initiatives. One such initiative is adoption of lean leadership to align core strategies with all functional areas of business. Leadership is likely to take place in a lean environment because improvements that happen are continual and can only be supported by leadership which understands this important aspect. The topic of lean leadership organizational buy ins speaks on how lean leadership could affect organizations that adopt lean and other quality tools. Purpose of the study This study has been undertaken to understand When leadership more of is likely to take place in lean . Leadership plays a very important role while adopting lean processes and how lean leadership can address the process problem. Application of leadership lenses to lean processes needs great foresight thought and creativity. It has been also observed that lean management and lean processes can happen only if leadership is able to effectively communicate the thought of continual improvement to bring in a lean organization and a future state of processes where everything of a firm process and procedure is continually improving and the best strategies to manage this change becomes a philosophy. Lean leadership is associated with such a change. This enables leadership vision to be clear as it paves the way for current state and is clear to everyone. It is this leadership vision which enables employees to think and act in a way that perpetrates continual improvement. Hence leadership buys ins for lean are very necessary. The purpose of the study is also to understand how leaders can not only use cost reduction but also reducing time-to-market improving service quality and reducing risk exposure by adopting lean methods . it has been also seen that there is overall productivity and efficiency in organizations holistically when leadership endorses lean methodology. Radnor Z. and Bucci G. 2007
Aij, Kjeld Harald; Visse, Merel; Widdershoven, Guy A M
The purpose of this study is to provide a critical analysis of contemporary Lean leadership in the context of a healthcare practice. The Lean leadership model supports professionals with a leading role in implementing Lean. This article presents a case study focusing specifically on leadership behaviours and issues that were experienced, observed and reported in a Dutch university medical centre. This ethnographic case study provides auto-ethnographic accounts based on experiences, participant observation, interviews and document analysis. Characteristics of Lean leadership were identified to establish an understanding of how to achieve successful Lean transformation. This study emphasizes the importance for Lean leaders to go to the gemba, to see the situation for one's own self, empower health-care employees and be modest. All of these are critical attributes in defining the Lean leadership mindset. In this case study, Lean leadership is specifically related to healthcare, but certain common leadership characteristics are relevant across all fields. This article shows the value of an auto-ethnographic view on management learning for the analysis of Lean leadership. The knowledge acquired through this research is based on the first author's experiences in fulfilling his role as a health-care leader. This may help the reader examining his/her own role and reflecting on what matters most in the field of Lean leadership.
Lipińska-Grobelny, Agnieszka; Papieska, Ewelina
This current study investigates the effect of lean management system on work attitudes of workers of two manufacturing companies. "Lean management" is a concept of work processes and human relations that determines company's productivity and profitability. Workers of two enterprises, the first one with lean production and the second one with old mass production, were compared for their readiness for change and job satisfaction (both emotional and cognitive aspect). The sample of 102 employees completed a battery of instruments such as: the Job Description Inventory by Neuberger and Allerbeck, the Job Affect Scale by Burke et al. and the Change-Readiness Scale by Kriegel and Brandt. Individuals from the lean manufacturing company were characterized by higher level of readiness for change, positive affect at work, and cognitive job satisfaction. In this approach the introduction of lean production positively affected company's human resource attitudes.
Iuga, Virginia; Kifor, Claudiu
The key to achieve a sustainable development lies in the customer satisfaction through improved quality, reduced cost, reduced delivery lead times and proper communication. The objective of the lean manufacturing system (LMS) is to identify and eliminate the processes and resources which do not add value to a product. The following paper aims to present a proposal of further development of integrated management systems in organizations through the implementation of lean shop floor management. In the first part of the paper, a dynamic model of the implementation steps will be presented. Furthermore, the paper underlines the importance of implementing a lean culture parallel with each step of integrating the lean methods and tools. The paper also describes the Toyota philosophy, tools, and the supporting lean culture necessary to implementing an efficient lean system in productive organizations
Aij, Kjeld Harald; Rapsaniotis, Sofia
As health care organizations face pressures to improve quality and efficiency while reducing costs, leaders are adopting management techniques and tools used in manufacturing and other industries, especially Lean. Successful Lean leaders appear to use a coaching leadership style that shares underlying principles with servant leadership. There is little information about specific similarities and differences between Lean and servant leaderships. We systematically reviewed the literature on Lean leadership, servant leadership, and health care and performed a comparative analysis of attributes using Russell and Stone's leadership framework. We found significant overlap between the two leadership styles, although there were notable differences in origins, philosophy, characteristics and behaviors, and tools. We conclude that both Lean and servant leaderships are promising models that can contribute to the delivery of patient-centered, high-value care. Servant leadership may provide the means to engage and develop employees to become successful Lean leaders in health care organizations.
Full Text Available This paper addresses the needs of SMEs manufacturing companies which due to their limited resources are often unable to introduce radical changes in their strategies. The main focus is on analyzing the principles of lean manufacturing and management regarding their potential contribution to building a company's competitive advantage. The paper analyses lean from a strategic management viewpoint while combining its implementation with achieving a competitive advantage. The ultimate result is a framework for lean implementation aimed at building a competitive advantage for companies. The proposed framework focuses on the idea of a closed loop with embedded sustainability.
Md. Mazharul Islam
Full Text Available Lean is a continuous journey to grow and excel the company. Any company want to develop and cope with the world pace must adopt lean. However, in most of the organizations the management culture or people’s mentality is not so good to embrace change. They have predestined mind set where no change is normally allowed. Lean is a cooperative way of working that involves all departments and all personnel to work together in a team for the betterment of the entire company. Without providing fixed solution of any problem it suggests the best way that people willingly accept to do. Lean normally deals with highest quality, shorter lead time and lowest cost. In Bangladesh, most of the garment manufacturing companies are experiencing a massive quality problem. We describe a case where traffic light, a tool of lean quality system was adopted to a garment manufacturing company in Bangladesh. We also provide the charts to contrast the before and after scenario in detail, in order to illustrate the company benefits. After the traffic light system being implemented, the quality status was improved, production capacity was increased; significant days were saved that enhanced the lead time and thus strengthen the supply chain.
McIntosh, Bryan; Sheppy, Bruce; Cohen, Ivan
There has been considerable interest in the implementation of practices imported from manufacturing into healthcare as a solution to rising healthcare spending and disappointing patient safety indicators. One approach that has attracted particular interest is Lean management and the purpose of this paper is to engage with this topic. Secondary research. Despite widespread enthusiasm about the potential of Lean management processes, evidence about its contribution to higher organisational performance remains inconsistent. This paper engages with the major Lean concepts of operations management and human resource management, including just-in-time, total quality management, total productive maintenance and does not engage in-depth with concepts related to employee empowerment, and training This paper contributes to the organisational management literature in healthcare by showing that although Lean management seems to have the potential to improve organisational performance it is far from a panacea against under performing hospitals. It informs policy making by suggesting that a progressive managerial philosophy has a stronger impact on healthcare performance than the adoption of practices from any particular managerial approach. This paper provides a critical evaluation of the impact of Lean practices in informing healthcare policy. The paper contributes to the organisational management literature in healthcare by showing that even though Lean management in healthcare appears to have the potential to improve organisational performance; there remain problems with its application.
Full Text Available The historical development of lean accounting is researched. The comparison of lean accounting and accounting is carried out. The article determines the lean accounting basic principles, which are the basis for the selection of main ten steps of upgrading to the system of lean accounting: the evaluation of the current situation and the expected development prospects of the enterprise; the development of the principles of implementing lean accounting; the determining the production parameters and methodology of the economic model construction; the organization of lean manufacturing environment and reducing most of the stock; the determining the flow of value creation; the rejection of variable accounting and reverse cancellation of all labor costs and the cost of materials; the rejection of tracking stocks and assign of the costs directly to the costs of sales when occurred; the definition of client-targeted spending; the relationship with suppliers and automation of the accounts payable; the relationship with customers and automation of the payments received.
Bahensky, James A; Roe, Janet; Bolton, Romy
The manufacturing industry has been using Lean Sigma for years in pursuit of continuous improvement to obtain a competitive advantage. The objectives of these efforts are to use the Lean techniques for reducing cycle times and the Six Sigma concepts for reducing product defects. The Iowa Business Council with several advocates worked with the University of Iowa Hospital and Clinics (UIHC) and two other Iowa hospitals to determine whether Lean Sigma is adaptable in healthcare. A team of 15 people at UIHC used the Kaizen Breakthrough Methodology over a five-day period in an aggressive identification and elimination of non-value added activities in Radiology CT scanning. The results exceeded the initial project objectives and indicated that Lean Sigma is applicable in healthcare. Overall, the Lean Sigma project increased revenue by approximately $750,000 per year. The Kaizen process proved to be successful and interesting. Within three days, the team installed new work flow processes. This implementation-oriented approach is what differentiates Lean Sigma from other quality improvement processes.
Knudsen, Lars Emmerik Damgaard
måder, og de hver af disse understøtter bestemte opfattelser af pædagogik og undervisning. Denne bog forsøger derfor give svar på, hvordan du kan forstå og omsætte relationerne mellem teori og praksis i dine pædagogiske studier og aktiviteter. Bogen giver dig viden om: • Hvordan og hvorfor teori og......Forbindelsen mellem teori og praksis er en grundlægende udfordring. Det gælder alle fag og professioner men ikke mindst for lærer- og pædagogstuderende, som netop formidler viden og som denne bog derfor adresserer. Den grundlæggende idé er, at teori og praksis kan relateres på flere forskellige...... praksis relaterer sig til hinanden som forskellige vidensformer, og hvordan disse forskellige former for viden ofte knytter sig til den kultur, som de optræder i. • Hvordan du kan analysere og syntetisere den måde, du i dit eget pædagogiske arbejde relaterer teori og praksis på, så du dermed også kan...
Avaliação qualitativa da implantação de práticas da produção enxuta: estudo de caso em uma fábrica de máquinas agrícolas Qualitative assessment of the implementation of lean production practices: a case study in a heavy machinery manufacturer
Tarcisio Abreu Saurin
Full Text Available Embora a maturidade de um sistema de produção enxuta (PE esteja associada principalmente à absorção dos princípios enxutos pela cultura organizacional, a avaliação de práticas operacionais associadas à PE fornece indícios acerca da implantação desse sistema. Este artigo apresenta uma avaliação qualitativa da implantação de práticas da PE em uma fábrica de máquinas agrícolas, a qual desde 2001 vem adotando a PE como filosofia de produção. A avaliação foi realizada na linha de montagem de colheitadeiras, usando quatro fontes de evidências: observação direta; entrevistas com 15 gerentes e supervisores; entrevistas com 30 operadores; análise de documentos relativos ao sistema de PE. Essas evidências permitiram o preenchimento de uma lista de verificação com 88 itens distribuídos ao longo de 12 típicas práticas da PE. Apesar das limitações da abordagem qualitativa utilizada (por exemplo, subjetividade na atribuição de níveis de desempenho a cada prática, foi possível identificar pontos fortes e fracos do sistema existente na empresa. Além disso, o estudo de caso também indicou diretrizes para o aperfeiçoamento dos métodos existentes de avaliação de implantação da PE.Even though the maturity of lean production (LP systems is mostly associated with the integration of lean principles into the organizational culture, the assessment of shop-floor practices associated with LP provides an overview of how lean a company is. In this context, this study presents a qualitative assessment of the implementation of LP practices in a heavy machinery manufacturer that has been adopting LP as its production philosophy since 2001. The assessment was undertaken in the harvesters assembly line based on four sources of evidence: direct observation; interviews with fifteen managers and supervisors; interviews with thirty operatives; and analysis of documents related to the LP system. Those evidences were a basis for
Remon Fayek Aziz
Full Text Available The productivity of the construction industry worldwide has been declining over the past 40 years. One approach for improving the situation is using lean construction. Lean construction results from the application of a new form of production management to construction. Essential features of lean construction include a clear set of objectives for the delivery process, aimed at maximizing performance for the customer at the project level, concurrent design, construction, and the application of project control throughout the life cycle of the project from design to delivery. An increasing number of construction academics and professionals have been storming the ramparts of conventional construction management in an effort to deliver better value to owners while making real profits. As a result, lean-based tools have emerged and have been successfully applied to simple and complex construction projects. In general, lean construction projects are easier to manage, safer, completed sooner, and cost less and are of better quality. Significant research remains to complete the translation to construction of lean thinking in Egypt. This research will discuss principles, methods, and implementation phases of lean construction showing the waste in construction and how it could be minimized. The Last Planner System technique, which is an important application of the lean construction concepts and methodologies and is more prevalent, proved that it could enhance the construction management practices in various aspects. Also, it is intended to develop methodology for process evaluation and define areas for improvement based on lean approach principles.
This book illustrates how goal-oriented, automated measurement can be used to create Lean organizations and to facilitate the development of Lean software, while also demonstrating the practical implementation of Lean software development by combining tried and trusted tools. In order to be successful, a Lean orientation of software development has to go hand in hand with a company's overall business strategy. To achieve this, two interrelated aspects require special attention: measurement and experience management. In this book, Janes and Succi provide the necessary knowledge to establish "
Kim, Christopher S; Spahlinger, David A; Kin, Jeanne M; Coffey, Richard J; Billi, John E
Lean Thinking is a management philosophy derived from the manufacturing industry, where Toyota has long been the gold standard. Health care organizations have started to apply this approach to patient care. After initial experimentation, the University of Michigan Health System (UMHS) has adopted Lean Thinking as its uniform approach to quality improvement and is striving to become a complete Lean organization. In 2005, the senior leadership selected an initial set of projects in areas that traced the patient's journey across different care settings within our health system. Four of the projects were as follows: orthopedic surgery clinic scheduling, radiation oncology therapy, peripherally inserted central catheter (PICC) services, and coordination of care to the outpatient setting. Lean Thinking encourages service providers to focus on value as defined by the customer and the relentless elimination of waste that impedes the flow of value. A series of learning projects were conducted to test whether Lean methods would work at UMHS. The following factors were found to be key to LEAN PROJECT SUCCESS: expert guidance for initial efforts, leadership in the form of clinical champions and senior management support of the improvement work, frontline worker engagement in mapping out "current state" processes, identifying waste and designing an improved "future state," using metrics to develop and track interventions, and defining realistic project scope. As UMHS's experience applying Lean Thinking to our patient care processes has grown, so have support, enthusiasm, and expertise within the organization. UMHS's Lean Thinking system, now known as the Michigan Quality System, has emerged as the core improvement strategy.
Patxi Ruiz de Arbulo-López
Full Text Available From the last two decades of the 20th Century on, many companies have adopted production strategies that could be termed “lean manufacturing”. Lean team leaders state that traditional costing systems fail to properly assess their operational improvements and therefore ask for new cost accounting methods. The search for a new accounting paradigm has led to important applied research and several accounting methods. In this paper we are going to show the state of the art in costing techniques used in companies that adopt lean manufacturing practices and we will be presenting an additional costing method, based on Activity-Based Costing, intended to cast light on the operational improvements achieved in companies that are just starting a maturity path towards lean manufacturing. This article examines how the approach is applied in the context of a manufacturing company.
Lean production methods for eliminating waste and improving processes in manufacturing are now being applied in healthcare. As the author shows, the methods are appropriate for redesigning hospital facilities. When used in an integrated manner and employing teams of mostly clinicians, the methods produce facility designs that are custom-fit to patient needs and caregiver work processes, and reduce operational costs. The author reviews lean methods and an approach for integrating them in the redesign of hospital facilities. A case example of the redesign of an emergency department shows the feasibility and benefits of the approach.
A. B. Hu
Full Text Available Lean buffering is the smallest buffer capacity necessary to ensure the desired production rate of a manufacturing system. In this paper, analytical methods for selecting lean buffering in serial production lines are developed under the assumption that the machines obey the Bernoulli reliability model. Both closed-form expressions and recursive approaches are investigated. The cases of identical and nonidentical machines are analyzed. Results obtained can be useful for production line designers and production managers to maintain the required production rate with the smallest possible inventories.
Análisis de la gestión estratégica y operativa de una empresa industrial del sector del mueble y reingeniería de procesos en la planta de producción de tapicería. Aplicación del modelo 7s y de las técnicas Kaizen, Seis Sigma y Lean Manufacturing
ESTEVE FERNÁNDEZ DE CORDOVA, JAVIER
Proyecto Confidencial Esteve Fernández De Cordova, J. (2008). Análisis de la gestión estratégica y operativa de una empresa industrial del sector del mueble y reingeniería de procesos en la planta de producción de tapicería. Aplicación del modelo 7s y de las técnicas Kaizen, Seis Sigma y Lean Manufacturing. http://hdl.handle.net/10251/34162. Archivo delegado
Petersen, Kristian R.; Madsen, Erik Skov; Bilberg, Arne
of Europe’s leading offshore wind power operators with more than 1,000 wind turbine generators in operation. By focusing on this company, in-depth insights into its operations and maintenance processes are investigated. Findings – Lean is identified to constitute an important first step before...... and resources can take place. The authors also establish a foundation for the development of a software tool to support the development of the modularisation of maintenance tasks. Originality/value – The present study contributes to the rather immature field of research on the operations and maintenance...
Full Text Available Purpose: Knowledge work productivity is a key area of improvement for many organisations. Lean approach is a sustainable way to achieve operational excellence and can be applied in many areas. The purpose of this novel study is to examine the potential of using lean approach for improving knowledge work practices. Design/methodology/approach: A systematic literature review has been carried out to study how lean approach is realised in knowledge work. The research is conceptual in nature and draws upon earlier research findings. Findings: This study shows that lean studies’ in knowledge work is an emerging research area. This study documents the methods and practices implemented in knowledge work to date, and presents a knowledge work continuum, which is an essential framework for effective lean approach deployment and to frame future research focus in knowledge work productivity. Research limitations/implications: This study structures the concept of knowledge work and outlines a concrete concept derived from earlier literature. The study summarises the literature on lean in knowledge work and highlights, which methods are used. More research is needed to understand how lean can be implemented in complex knowledge work environment and not only on the repetitive knowledge work. The limitations of this research are due to the limited availability of previous research. Practical implications: To analyse the nature of knowledge work, we implicate the areas where lean methods especially apply to improving knowledge work productivity. When applying lean in knowledge work context the focus should be using the people better and improving information flow. Originality/value: This study focuses on adapting lean methods into a knowledge work context and summarises earlier research done in this field. The study discusses the potential to improve knowledge work productivity by implementing lean methods and presents a unique knowledge work continuum to
Full Text Available The purpose of this paper is to investigate and understand how tools and principles of Lean philosophy can be adopted to improve the effectiveness of engineering education by providing services beyond the competition and costs below the competition, and how engineering education can provide better prepared engineering professionals capable to work in dynamic Lean environments by developing multidisciplinary knowledge and skills. Paper will be based on analysis of relevant scientific and professional literature sources, including certain elements of description, classification, explanation and prediction. The authors will use detailed literature review to explain complex relationship and interdependence between Lean philosophy and engineering education and answer the question what benefits modern Lean enterprises may expect from properly educated and qualified engineers and how application of Lean tools and principles can improve the system of engineering education.
Krause-Jensen, Lone; Neubauer, Turi; Landbo, Anne Sofie
Projektet har undersøgt sammenhængen mellem teori og praksis inden for udvalgte samfundsvidenskabelige fag på bioanalytikeruddannelsen. Teoretisk tages udgangspunkt i Goodlads fem perspektiver på curriculumudvikling: Niveau 1 (ideologisk curriculum), niveau 2 (formelt curriculum), niveau 3 (opfat...
Thanki, Shashank; Govindan, Kannan; Thakkar, Jitesh
sensitivity analysis of three AHP models, we propose bundles of lean and green practices to surmount the market challenges faced by SMEs. These results are used to develop an integrated framework for lean-green system to guide SMEs towards sustainable growth. The findings are expected to benefit policy makers...... and industrial practitioners of SMEs to focus on a few vital issues to facilitate both lean and green manufacturing implementation and assessment....
Doreswamy, Rajiv, N.; Self, Timothy A.
This viewgraph presentation describes test strategies and lean philisophies and practices that are applied to Ares Launch Vehicles. The topics include: 1) Testing strategy; 2) Lean Practices in Ares I-X; 3) Lean Practices Applied to Ares I-X Schedule; 4) Lean Event Results; 5) Lean, Six Sigma, and Kaizen Practices in the Ares Projects Office; 6) Lean and Kaizen Success Stories; and 7) Ares Six Sigma Practices.
Jorma, Tapani; Tiirinki, Hanna; Bloigu, Risto; Turkki, Leena
Purpose - The purpose of this study is to evaluate how LEAN thinking is used as a management and development tool in the Finnish public healthcare system and what kind of outcomes have been achieved or expected by using it. The main focus is in managing and developing patient and treatment processes. Design/methodology/approach - A mixed-method approach incorporating the Webropol survey was used. Findings - LEAN is quite a new concept in Finnish public healthcare. It is mainly used as a development tool to seek financial savings and to improve the efficiency of patient processes, but has not yet been deeply implemented. However, the experiences from LEAN initiatives have been positive, and the methodology is already quite well-known. It can be concluded that, because of positive experiences from LEAN, the environment in Finnish healthcare is ready for the deeper implementation of LEAN. Originality/value - This paper evaluates the usage of LEAN thinking for the first time in the public healthcare system of Finland as a development tool and a management system. It highlights the implementation and achieved results of LEAN thinking when used in the healthcare environment. It also highlights the expectations for LEAN thinking in Finnish public healthcare.
Brännmark, Mikael; Holden, Richard J.
Background Lean Production is a dominant approach in Swedish and global manufacturing and service industries. Studies of Lean’s employee effects are few and contradictory. Purpose Employee effects from Lean are likely not uniform. This paper investigates the effect of employees' participation on their experiences of Lean. Method This study investigated how different packages of employee participation in Lean affected manufacturing workers’ experiences of Lean. During 2008–2011, qualitative and quantitative data were collected from Swedish manufacturing companies participating in the national Swedish Lean Production program Produktionslyftet. Data from 129 surveys (28 companies), 39 semi-structured interviews, and 30 reports were analyzed. In the main analysis, comparisons were made of the survey-reported Lean experiences of employees in three groups: temporary group employees (N = 36), who participated in Lean mostly through intermittent projects; continuous group employees (N = 69), who participated through standing improvement groups; and combined group employees (N = 24), who participated in both ways. Results Continuous group employees had the most positive experience of Lean, followed by the combined group. Temporary group employees had the least positive experiences, being less likely than their counterparts to report that Lean improved teamwork, occupational safety, and change-related learning, decision making, and authority. Conclusions These findings support the importance of continuous, structured opportunities for participation but raise the possibility that more participation may result in greater workload and role overload, mitigating some benefits of employee involvement. Consequently, companies should consider involving employees in change efforts but should attend to the specific design of participation activities. PMID:24665370
Yunus, Riduan; Noor, Siti Rahimah Mohd; Halid Abdullah, Abd; Nagapan, Sasitharan; Hamid, Abdul Rahim Abdul; Tajudin, Saiful Azhar Ahmad; Rohani Mat Jusof, Siti
Productivity in the manufacturing process of building components can be increased by optimising each advantage that is available in each activity. Identification of critical success factors (CSFs) for lean thinking in the Industrialised Building System (IBS) will be able to minimise cost and reduce time needed to complete a project. The focus of lean thinking in construction is on the production process and the client’s requirement. In developing countries such as Malaysia, the integration of lean thinking in IBS applications is still low and there is a shortage of comprehensive strategies to integrate lean thinking. As key stakeholders, feedback from contractors, manufacturers, developers and the local authority will be able to help the identification of CSFs in integrating lean thinking in IBS applications. The data was collected through a questionnaire survey and analysed quantitatively. There are 31 CSFs for lean thinking in IBS which have been identified in this study. A conceptual model was developed to assist researchers in investigating the influences of CSFs for lean thinking in IBS applications. This study will assist construction players to improvise their manufacturing process in the implementation of IBS to eliminate unnecessary activities and focus instead on significant processes without generating physical and non-physical waste.
Full Text Available This paper describes the implementation of lean tools in a wind mill-electrical control panel assembly plant in south India as a lean manufacturing improvement initiative. This involved mapping the activities of the firm, identifying opportunities for improvement and then undertaking with the firm an improvement programme. Current state map is prepared to describe the existing position and various problem areas. Takt time calculations are carried out to set the pace of production. Future state map is prepared to show the proposed improvement action plans. The achievements of value stream implementation are reduction in lead time, cycle time and inventory level. It was found that even a small company can make significant improvements by adopting lean principles.
Full Text Available The purpose of this article is to show the usefulness of Lean Manufacturing techniques when approaching the environmental issues. Green Lean Methodology presentation in seven steps with afferent tools and techniques provides a practical framework. Green Lean Methodology follows the Deming’s cycle (PDCA and it aims to achieve the continuous incremental improvement. Increasing the resource use effectiveness is achieved not only by protecting natural resources, but also by increasing productivity. These environmental gains through productivity are possible by continuously reducing losses in transformation processes, by designing/redesigning products and services in order to prevent undesirable environmental effects, by designing the control procedures in the processing flows, by increasing the capital investment in more efficient technology, by continuously improving work performance, by changing the perceptions of senior managers and by a more efficient and effective research and innovation. Keywords
Higor dos Reis Leite
Full Text Available This article presents an in-depth bibliographic study about the creation, principles, evolution, and practices of the lean philosophy oriented to the services sector. More than 70 papers about “lean thinking” – specially with focus on services – have been carefully reviewed. It presents the principles of lean service in an organized way, companies applying lean service, and best practices and tools in the implementation of lean service. It shows that lean service does not have a single or specific model of tools, practices or standards. In fact, it is a mix of tools and practices that must be applied according the situation found to be improved. Despite the lack of a standards and methodology for use in services, its best practices, inherited from manufacturing, when applied to services can generate large economic and financial results, as well as improvement of workers’ behavior. But, like any change process, this study shows that the application of lean in services also suffers resistance. There might be limitations when evaluating lean practices and principles to services, specially those that have not yet been well defined and reported. Other limitations are due to the scarce articles in the literature. However, this research showed that the use of the lean philosophy in services proved to be effective and quite worthwhile. Several cases analyzed presented significant gains and confirmed an increasing and promising future for service companies “thinking lean”.
Teich, Sorin T; Faddoul, Fady F
The evolution of production systems is tightly linked to the story of Toyota Motor Company (TMC) that has its roots around 1918. The term "lean" was coined in 1990 following the exploration of the Toyota model that led to the "transference" thesis sustaining the concept that manufacturing problems and technologies are universal problems faced by management and that these concepts can be emulated in non-Japanese enterprises. Lean is a multi-faceted concept and requires organizations to exert effort along several dimensions simultaneously; some consider a successful implementation either achieving major strategic components of lean, implementing practices to support operational aspects, or providing evidence that the improvements are sustainable in the long term. The article explores challenges and opportunities faced by organizations that intend incorporating lean management principles and presents the specific context of the healthcare industry. Finally, the concepts of "essential few" and customer value are illustrated through a simple example of process change following lean principles, which was implemented in a dental school in the United States.
Eswaramoorthi, M; John, Mervyn; Rajagopal, C Arjun; Prasad, P S S; Mohanram, P V
With the current state of the global economy, demand for various products plummeting. To sustain in the market, companies have to reduce cost and improve quality. Today, companies have started implementing new philosophies like TQM, TPM, six sigma and lean manufacturing techniques to remain competitive in the market. Lean manufacturing is an emerging philosophy which continuously strives to reduce waste. The main objective of analyzing the assembly line with a lean perspective is to identify the areas related to human interface with other systems that could lead to the generation of waste. Improper workplace design leads to unreasonable mental or physical burden and results in waste generation like slow work (delay and inventory), and defects, which is named as muri waste. An attempt has been made in this paper to locate muri waste and create a "Lean assembly line". The proposed method, based on the use of Rapid Upper Limb Assessment (RULA) with CATIA V5 platform, has allowed the measurement of a large set of operator posture parameters and assessment of ergonomic stresses. Based on the results, the process stations in the assembly line were redesigned to prevent the generation of waste.
Full Text Available Recently, new approaches to product development have emerged that focus on idea generation techniques and customer itself. One of them is the Lean Startup method that is described in this article along with the Lean Canvas method. The main goal of the article is to demonstrate the application of both methods to an innovative product development focused on providing interactive trips for families with children. The development of the product during individual phases is described and application of the Lean Startup and Lean Canvas principles is demonstrated. Finally, benefits of both methods contributing to the product success are discussed. Similar case studies start emerging worldwide, however in the Czech context are quite rare.
Proponents of Lean Philosophy believe that successful businesses must reduce waste in working time and resources to a minimum, and maximise their use in productive work. The productive work of the Acute Medical Unit is to provide effective clinical management to a daily cohort of acutely ill patients. Many Clinicians are cynical about Lean. In this article, Dr Caldwell discusses how many clinicians complain of too much crap in the workplace, which gets in the way of swift, safe high quality clinical care. He argues that "Cutting the Crap" in the Acute Medical Unit is entirely consistent with Lean approaches to management of complex systems.
Baker, G Ross
For more than a decade, healthcare organizations across Canada have been using Lean management tools to improve care processes, reduce preventable adverse events, increase patient satisfaction and create better work environments. The largest system-wide effort in Canada, and perhaps anywhere, is currently under way in Saskatchewan. The jury is still out on whether Lean efforts in that province, or elsewhere in Canada, are robust enough to transform current delivery systems and sustain new levels of performance. This issue of Healthcare Quarterly features several articles that provide a perspective on Lean methods in healthcare. Copyright © 2014 Longwoods Publishing.
Ben-Tovim, David I; Bassham, Jane E; Bolch, Denise; Martin, Margaret A; Dougherty, Melissa; Szwarcbord, Michael
Lean thinking is a method for organising complex production processes so as to encourage flow and reduce waste. While the principles of lean thinking were developed in the manufacturing sector, there is increasing interest in its application in health care. This case history documents the introduction and development of Redesigning Care, a lean thinking-based program to redesign care processes across a teaching general hospital. Redesigning Care has produced substantial benefits over the first two-and-a-half years of its implementation, making care both safer and more accessible. Redesigning Care has not been aimed at changing the specifics of clinical practice. Rather, it has been concerned with improving the flow of patients through clinical and other systems. Concepts that emerged in the manufacturing sector have been readily translatable into health care. Lean thinking may play an important role in the reform of health care in Australia and elsewhere.
Kim, Christopher S; Spahlinger, David A; Kin, Jeanne M; Billi, John E
With health care costs continuing to rise, a variety of process improvement methodologies have been proposed to address the reported inefficiencies in health care delivery. Lean production is one such method. The management philosophy and tools of lean production come from the manufacturing industry, where they were pioneered by Toyota Motor Corporation, which is viewed as the leader in utilizing these performance improvement methods. Lean has already enjoyed tremendous success in improving quality and efficiency in both the manufacturing and the service sector industries. Health care systems have just begun to utilize lean methods, with reports of improvements just beginning to appear in the literature. We describe some of the basic philosophy and principles of lean production methods and how these concepts can be applied in the health care environment. We describe some of the early success stories and ongoing endeavors of lean production in various health care organizations. We believe the hospital is an ideal setting for use of the lean production method, which could significantly affect how health care is delivered to patients. We conclude by discussing some of the potential challenges in introducing and implementing lean production methods in the health care environment. Lean production is a novel approach to delivering high-quality and efficient care to patients, and we believe that the health care sector can anticipate the same high level of success that the manufacturing and service industries have achieved using this approach. Hospitalists are primed to take action in delivering care of greater quality with more efficiency by applying these new principles in the hospital setting. (c) 2006 Society of Hospital Medicine.
Full Text Available Recently, Lean Production (Lean has become a prevailing management concept in Sweden. However, previous research seems to show that the Lean concept and the impact of Lean vary considerably between organizations. This paper illustrates some key methodological issues that need to be considered when researching loosely defined management concepts such as Lean. The paper is based on a review of the literature and five comparative Swedish cases studies. Our study indicates that Lean has changed over time and that operationalization and interpretations of the concept vary considerably. This study concludes that future Lean studies should include a thorough assessment of the Lean interventions, study settings, and in particular non-Lean factors mediating the outcomes of Lean-inspired change programs.
Serafinas, Dalius; Ruželė, Darius
Remiantis evoliucijos tyrimų modeliais bei autorių sudarytu evoliucionuojančios organizacijos modeliu,straipsnyje analizuojama Lean vadybos metodologija ir tiriama, kaip evoliucionuoja ją įgyvendinančios Lietuvosgamybinės organizacijos. The purpose of this paper is to examine the evolution of Lean organizations.Design/methodology/approach: a conceptual literature on the evolution of species, organisms and organizations was reviewed and an original model (framework) of the evolution of orga...
Abreu, Antonio; Calado, João; Requeijo, José
Nowadays, companies in global markets have to achieve high levels of performance and competitiveness to stay "alive".Within this assumption, the building maintenance cannot be done in a casual and improvised way due to the costs related. Starting with some discussion about lean management and building maintenance, this paper introduces a model to support the Lean Building Maintenance (LBM) approach. Finally based on a real case study from a Portuguese company, the benefits, challenges and difficulties are presented and discussed.
Matthiesen, Rikke Vestergaard; Johansen, John
triggered. This paper reports on exploratory studies from a multinational company adopting centrally managed pilot projects as a transformation mechanism for continuous change towards a lean business system and an organizational culture of continuous improvements (CI). Competitive pressure demands...... from a multinational company adopting centrally managed pilot projects as a transformation mechanism for continuous change towards a lean business system and an organizational culture of continuous improvements (CI)....
Due to the globalization today the competition in the market has in- creased and it requires flexibility and produce according to customer demand. In order to reduce the cost of wages industrial companies are now considering moving the manufacturing to low-cost countries. To keep up with the competition in the market without moving the manu- facturing abroad, Lean Automation was developed. The concept of Lean Automation is to reduce the perceived complexity with automa- tion and make automati...
Merlino, Joseph P; Petit, Jorge; Weisser, Lydia; Bowen, Jill
Lean and other quality management methodologies have been used by industry and manufacturing for many years. More recently they have been adopted by health care. The authors describe their experience with the lean way of continuous quality improvement, first developed by Toyota, at one of New York's largest behavioral health departments. The relevance and application of these methodologies to the mental health sector is presented.
Aij,Kjeld Harald; Rapsaniotis,Sofia
Kjeld Harald Aij, Sofia Rapsaniotis VU University Medical Center, Division Acute Care and Surgery, Amsterdam, The Netherlands Abstract: As health care organizations face pressures to improve quality and efficiency while reducing costs, leaders are adopting management techniques and tools used in manufacturing and other industries, especially Lean. Successful Lean leaders appear to use a coaching leadership style that shares underlying principles with servant leadership. There is little inform...
Noor Azlina Mohd Salleh; Salmiah Kasolang; Ahmed Jaffar
Green Lean Total Quality Management (LTQM) Human Resource Management (HRM) System is a system comprises of HRM in Environmental Management System (EMS) practices which is integrated to TQM with Lean Manufacturing (LM) principles. HRM is essential especially in dealing with low motivation and less productive employees. The ultimate goal of this system is to focus on achieving total human resource development that is motivated and capable to optimize their creativity to be a part of Green and L...
National Aeronautics and Space Administration — A critical barrier for GA to serve as viable and volume personal transportation is the lack of a cost-effective, yet open-growth, Lean Design and manufacturing...
Full Text Available Background: The lean production is a well-established managerial concept, which helps companies to provide the customer value and to reduce cost. Recently it gains a lot of attention among the remanufacturers. In this paper the assumption is made that remanufacturing process is more sustainable, if there will be efficient utilization of the resources. The resource utilization is efficient when there is no waste of resources. The implementation of lean principles and tools into a remanufacturing process can benefit to improved sustainability but also it suffers some constrains, which are identified in this paper. Methods: The research methodology consists of a literature review, where research papers from the Scopus, Science Direct and Business Source Premier databases were used. The search criterion was the phrase "lean remanufacturing". On the basis of literature review the lean remanufacturing problems are identified. The framework for lean remanufacturing analysis was established. Author presents also case studies on assessment of the leanness of remanufacturing process and discusses the potential for waste elimination in order to improve sustainability of remanufacturing process. Results: Problem identification and analysis framework of lean remanufacturing process is discussed. The case studies results are analysed in the context of the finding of the literature review. The advantages and constrains of lean remanufacturing are discussed. Conclusions: A remanufacturing process is more complex than the respective production process. The implementation of lean production principles and tools into remanufacturing process is at a very early stage comparing to the traditional manufacturing. There are evidences from the industrial studies and the academic research on lean remanufacturing benefits. There is a need to distinguish between lean remanufacturing on an operational and a strategic level. From the perspective of sustainability of
The inventory cost has important impact on the production cost. In order to get the maximum circulation of funds of enterprise with minimum inventory cost, the inventory control with Lean Six Sigma is presented in supply chain management. The inventory includes both the raw material and the semi-finished parts in manufacturing process. Though the inventory is often studied, the inventory control in manufacturing process is seldom mentioned. This paper reports the inventory control from the perspective of manufacturing process by using statistical techniques including DMAIC, Control Chart, and Statistical Process Control. The process stability is evaluated and the process capability is verified with Lean Six Sigma philosophy. The demonstration in power meter production shows the inventory is decreased from 25% to 0.4%, which indicates the inventory control can be achieved with Lean Six Sigma philosophy and the inventory cost in production can be saved for future sustainable development in supply chain management.
Between the most effective techniques of manufacturing management is considered the Lean Engineering. The term “lean engineering” was created by Japanese manufacturers. The high efficiency of this method resulted in a meaningful growth in concern in the philosophy of Lean among European companies, and consequently the use of its European markets. Lean philosophy is an approach to manufacturing to minimize the use of all resources, including time. These are resources that are used in the company for a variety of activities. This implies, first identify and then eliminate activities which does not generate added value in the field of design, manufacturing, supply chain management, and customer relations. The producers of these principles not only employ teams multi-professional employees at all levels of the organization, but also use a more automated machines to produce large quantities of products with a high degree of diversity. Lean Engineering is to use a number of principles and practical guidelines that allow you to reduce costs by eliminating absolute extravagance, and also simplification of all manufacturing processes and maintenance. Nowadays it could be applied the powerful engineering programs to realize the concept of Lean Engineering. They could be described using the term CAD/CAM/CAE. They consist of completely different packages for both the design of elements, as well process design. Their common feature is generally considered with their application area. They are used for computer programs assisting the design, development and manufacturing phases of a manufacturing process. The idea of the presented work is to use the Siemens NX software for aiding the process of Lean Engineering system creating. The investigated system is a robotized workcell. In the NX system are created the components of the designed workcell such as machine tools, as industrial robot, as conveyors and buffers. The system let to functionally link these components to
Osezua Aikhuele, Daniel; Mohd Turan, Faiz
In the effort for manufacturing companies to meet up with the emerging consumer demands for mass customized products, many are turning to the application of lean in their product development process, and this is gradually moving from being a competitive advantage to a necessity. However, due to lack of clear understanding of the lean performance measurements, many of these companies are unable to implement and fully integrated the lean principle into their product development process. Extensive literature shows that only few studies have focus systematically on the lean product development performance (LPDP) evaluation. In order to fill this gap, the study therefore proposed a novel hybrid model based on Fuzzy Reasoning Approach (FRA), and the extension of Fuzzy-AHP and Fuzzy-TOPSIS methods for the assessment of the LPDP. Unlike the existing methods, the model considers the importance weight of each of the decision makers (Experts) since the performance criteria/attributes are required to be rated, and these experts have different level of expertise. The rating is done using a new fuzzy Likert rating scale (membership-scale) which is designed such that it can address problems resulting from information lost/distortion due to closed-form scaling and the ordinal nature of the existing Likert scale.
Sorin T. Teich
Full Text Available The evolution of production systems is tightly linked to the story of Toyota Motor Company (TMC that has its roots around 1918. The term “lean” was coined in 1990 following the exploration of the Toyota model that led to the “transference” thesis sustaining the concept that manufacturing problems and technologies are universal problems faced by management and that these concepts can be emulated in non-Japanese enterprises. Lean is a multi-faceted concept and requires organizations to exert effort along several dimensions simultaneously; some consider a successful implementation either achieving major strategic components of lean, implementing practices to support operational aspects, or providing evidence that the improvements are sustainable in the long term. The article explores challenges and opportunities faced by organizations that intend incorporating lean management principles and presents the specific context of the healthcare industry. Finally, the concepts of “essential few” and customer value are illustrated through a simple example of process change following lean principles, which was implemented in a dental school in the United States.
Teich, Sorin T.; Faddoul, Fady F.
The evolution of production systems is tightly linked to the story of Toyota Motor Company (TMC) that has its roots around 1918. The term “lean” was coined in 1990 following the exploration of the Toyota model that led to the “transference” thesis sustaining the concept that manufacturing problems and technologies are universal problems faced by management and that these concepts can be emulated in non-Japanese enterprises. Lean is a multi-faceted concept and requires organizations to exert effort along several dimensions simultaneously; some consider a successful implementation either achieving major strategic components of lean, implementing practices to support operational aspects, or providing evidence that the improvements are sustainable in the long term. The article explores challenges and opportunities faced by organizations that intend incorporating lean management principles and presents the specific context of the healthcare industry. Finally, the concepts of “essential few” and customer value are illustrated through a simple example of process change following lean principles, which was implemented in a dental school in the United States. PMID:23908857
Full Text Available A key ingredient to underpin process improvement is a robust, reliable, repeatable measurement system. Process improvement activity needs to be supported by accurate and precise data because effective decision making, within process improvement activity, demands the use of “hard” data. One of the oldest and most established process improvement methods is Deming’s Plan-Do-Check-Act (PDCA cycle which is reliant on the check phase, a measurement activity where data is being gathered and evaluated. Recent expansions of the PDCA such as the Six-Sigma Define-Measure-Analyse-Improve-Control (DMAIC methodology place significant importance upon measurement. The DMAIC cycle incorporates the regimented requirement for the inclusion of measurement system analysis (MSA into the breakthrough strategy. The call for MSA within the DMAIC cycle is to provide the improvement activity with a robust measurement system that will ensure a pertinent level of data during any validation process. The Lean methodology is heavily centred on the removal of the seven Mudas (wastes from a manufacturing process: defects, overproduction, transportation, waiting, inventory, motion and processing. The application of lean, particularly within the manufacturing industry, has led to a perception that measurement is a waste within a manufacturing process because measurement processes identify defective products. The metrologists’ pursuit for measurement excellence could be construed as a hindrance by the “cost down” demands being perpetrated from the same organisation’s lean policy. So what possible benefits does enforcing the regimes of the lean and quality philosophies upon the measurement process have and how does this ultimately enhance the process improvement activity? The key fundamental to embed with any process improvement is the removal of waste. The process improvement techniques embedded within lean and quality concepts are extremely powerful practices in the
González de Diego, Clara Mª
La metodología Lean Manufacturing y la filosofía Seis Sigma han cobrado un papel de vital importancia en el mundo de la industria y de la producción. Es por ello que, a partir de la propuesta lanzada por la Asociación Española para la Calidad (AEC), se ha decidido observar el grado de explicación de una serie de conceptos de calidad (conceptos básicos, diseño de experimentos, normas de calidad y Seis Sigma) y de producción (MRP, JIT y Lean Manufacturing) en las titulacione...
Collar, Ryan M; Shuman, Andrew G; Feiner, Sandra; McGonegal, Amy K; Heidel, Natalie; Duck, Mary; McLean, Scott A; Billi, John E; Healy, David W; Bradford, Carol R
Lean is a management system designed to enhance productivity by eliminating waste. Surgical practice offers many opportunities for improving efficiency. Our objective was to determine whether systematic implementation of lean thinking in an academic otolaryngology operating room improves efficiency and profitability and preserves team morale and educational opportunities. In an 18-month prospective quasi-experimental study, a multidisciplinary task force systematically implemented lean thinking within an otolaryngology operating room of an academic health system. Operating room turnover time and turnaround time were measured during a baseline period; an observer-effect period in which workers were made aware that their efficiency was being measured but before implementing lean changes; and an intervention period after redesign principles had been used. The impact on teamwork, morale, and surgical resident education were measured during the baseline and intervention periods through validated surveys. A profit model was applied to estimate the financial implications of the study. There was no difference between the baseline and observer-effect periods of the study for turnover time (p = 0.98) or turnaround time (p = 0.20). During the intervention period, the mean turnover time and turnaround time were significantly shorter than during the baseline period (29 vs 38 minutes; p improved morale after implementation (p = 0.011). Educational metrics were unchanged before and after implementation. The annual opportunity revenue for the involved operating room is $330,000; when extrapolated throughout the operating rooms, lean thinking could create 6,500 hours of capacity annually. Application of lean management techniques to a single operating room and surgical service improved operating room efficiency and morale, sustained resident education, and can provide considerable financial gains when scaled to an entire academic surgical suite. Copyright © 2012. Published by
Damle, Aneel; Andrew, Nathan; Kaur, Shubjeet; Orquiola, Alan; Alavi, Karim; Steele, Scott R; Maykel, Justin
Lean processes involve streamlining methods and maximizing efficiency. Well established in the manufacturing industry, they are increasingly being applied to health care. The objective of this study was to determine feasibility and effectiveness of applying Lean principles to an academic medical center colonoscopy unit. Lean process improvement involved training endoscopy personnel, observing patients, mapping the value stream, analyzing patient flow, designing and implementing new processes, and finally re-observing the process. Our primary endpoint was total colonoscopy time (minutes from check-in to discharge) with secondary endpoints of individual segment times and unit colonoscopy capacity. A total of 217 patients were included (November 2013-May 2014), with 107 pre-Lean and 110 post-Lean intervention. Pre-Lean total colonoscopy time was 134 min. After implementation of the Lean process, mean colonoscopy time decreased by 10 % to 121 min (p = 0.01). The three steps of the process affected by the Lean intervention (time to achieve adequate sedation, time to recovery, and time to discharge) decreased from 3.7 to 2.4 min (p Lean patient satisfaction surveys demonstrated an average score of 4.5/5.0 (n = 73) regarding waiting time, 4.9/5.0 (n = 60) regarding how favorably this experienced compared to prior colonoscopy experiences, and 4.9/5.0 (n = 74) regarding professionalism of staff. One hundred percentage of respondents (n = 69) stated they would recommend our institution to a friend for colonoscopy. With no additional utilization of resources, a single Lean process improvement cycle increased productivity and capacity of our colonoscopy unit. We expect this to result in increased patient access and revenue while maintaining patient satisfaction. We believe these results are widely generalizable to other colonoscopy units as well as other process-based interventions in health care.
Sjöstrand, Niklas; Larsson, Mona-Liza
AbstractWhen a product has been sold to a customer a new market arises for the company to earn profit from and to differentiate itself within. According to Bartwal, et al. (2010) the after sales market generally does not provide great revenues but good profits of the total revenue. In order to gain competiveness and live up to customer’s expectations a company needs to be efficient (Atkinson, 2004). He continuous that this can be accomplished if companies implement Lean. Lean is different too...
Fliedner, Gene; Mathieson, Kieran
The authors examined business practitioners' preferences for higher education curricula design in general and for what graduates should know about Lean, or waste-reduction efforts. The authors conducted a Web-based survey and found that practitioners are not as concerned about graduates' possessing specific technical skills as they are about them…
Christian F. Fricke
Full Text Available This two-part publication about Lean practices by Viriginia’s wood products and furniture manufacturing industries reports results from researching the awareness, the implementation status, the business results, and the need for external implementation support of Virginian companies. This second manuscript focuses on business results and the need for external implementation support. Except for “sales per employee,” where less than half of respondents reported an improvement due to the implementation of Lean in their operation, a majority of respondents indicated improved business results for “lead time,” “on-time delivery,” “inventory turnover,” and “cost per unit.” With respect to the need for external Lean implementation support, only 23 percent of respondents answered in the affirmative. “Training management,” “training shop floor employees,” and “implementing [Lean] with extensive employee involvement” were, with 67, 58, and 48 percent frequencies, the most often named forms of Lean implementation support requested. Results from this study seem to indicate an opportunity to support the well-being of Virginia’s wood products and furniture manufacturing industries through improved communication of the benefits of Lean and offering specific types of training to companies.
Ahmad, Md Fauzi; Ting, Neo Yeong; Nor, Nik Hisyamudin Muhd; Wei, Chan Shiau; Hassan, Mohd Fahrul; Hamid, Nor Aziati Abdul
Nowadays, lean practices are implemented in many manufacturing and services companies. Lean practices are implemented in order to minimize wastes while maximise the overall performances in an organisation. In service sector, lean practices are importance to ensure value added services can be delivered to customers. However, Malaysia automotive companies cannot compete with Japanese automotive companies in terms of their customer satisfaction. The purpose of this study is to compare the lean practice between Japanese and Malaysia automotive service centres. A total of 80 questionnaires out of 100 distributed questionnaires were responded and this represented as 80% of response rate. The Mann-Whitney test result shows that there were four out of five factors of lean practices have significant differences between Japanese and Malaysia automotive service centres, which are TPM, JIT, Kanban, and 5S. VSM has not significant difference between ownerships. In addition, TPM, JIT, Kanban, VSM and 5S were higher practices in Japanese companies against Malaysia companies. Many Malaysia companies are still in the journey of lean practices and they need recommendation guidance to compete with other long-term established companies. Based on the survey result, the significant differences are identified as weak points of Malaysia companies as an opportunity to improve. Moreover, the significance of this study can help researchers and industry players to improve lean practices in automotive service industry.
Andreia Macedo Gomes
Full Text Available Recently, the Lean philosophy is gaining importance due to a competitive environment, which increases the need to reduce costs. Lean practices and tools have been applied to manufacturing, services, supply chain, startups and, the next frontier is healthcare. Most lean techniques can be easily adapted to health organizations. Therefore, this paper intends to summarize Lean practices and tools that are already being applied in health organizations. Among the numerous techniques and lean tools used, this research highlights the Simulation. Therefore, in order to understand the use of Simulation as a Lean Healthcare tool, this research aims to analyze, through the simulation technique, the operational dynamics of the service process of a fictitious hospital emergency unit. Initially a systematic review of the literature on the practices and tools of Lean Healthcare was carried out, in order to identify the main techniques practiced. The research highlighted Simulation as the sixth most cited tool in the literature. Subsequently, a simulation of a service model of an emergency unit was performed through the Arena software. As a main result, it can be highlighted that the attendants of the built model presented a degree of idleness, thus, they are able to atend a greater demand. As a last conclusion, it was verified that the emergency room is the process with longer service time and greater overload.
Michelsen, Aage U
I kapitlet redegøres for, hvordan begrebet Lean opstod som en karakteristik af Toyota Production System (TPS), der igen har sin rod i scientific management. Gennem eksempler illustreres det, at centrale Lean-principper således har været anvendt i årtier. Der argumenteres for, at Lean i mange...
de Koning, H.; Does, R.J.M.M.; Bisgaard, S.
Lean Thinking and Six Sigma are typically considered as separate approaches to process innovation, with complementary strengths. When combined as Lean Six Sigma, this approach provides a unified framework for systematically developing innovations. Lean Six Sigma can also bring about significant
Full Text Available The main purpose of the paper is the analysis of a process of change focusing particularly on the concept of slimmed production (Lean and its implementation in the enterprise. A case study method was chosen as a research tool because it offers wide array of techniques and means of gaining and analysing data.
Full Text Available Six Sigma as a quality improvement framework has gained considerable popularity in the past two decades. Its extension Lean Six Sigma has also been embraced by many organizations for improvement of quality and business competitiveness. One important factor for the popularity of Six Sigma and Lean Six Sigma is their potential for improving service systems, in contrast to the conventional perceptions that only manufacturing systems can benefit from statistics-based methodologies. There are however a number of issues related to the nature of service systems that must be resolved before the full benefits of Lean Six Sigma can be realized. In this paper, these issues are discussed from a practical point of view from three angles: analytical, organizational, and personal. Awareness of the existence of such issues, if not the answers to all of them, is a pre-requisite to effective adoption of Lean Six Sigma tools.
Alexandra Mirela Cristina MUNTEANU
This paper analyzes the benefits of Lean Six Sigma in comparison with Lean and Six Sigma, traditional improvement methodologies. The introduction highlights the appearance of Lean Six Sigma, early 2000s, as well as the benefits brought by the integrated approach. The following parts of the study emphasize the main differences between methodologies and their commonalities based on their synergy. Finally the advantages of Lean Six Sigma versus Lean and Six Sigma are analyzed and systematized by...
clear distribution media becomes translucent once infused with the corn syrup mixture and does not obstruct the view. Note the setup is designed...defects in concrete structures [13,14] but the scale of faults in these structures is macroscopic as opposed to microscopic scale damage which...336. 14. Chen G, Mu H. Pommerenke D. Drewniak JL. Damage Detection of Reinforced Concrete Beams with Novel Distributed Crack/Strain Sensors
D'Errico, F.; Perricone, G.; Oppio, R.
From an environmental point of view, lighter metals like aluminum and magnesium are unclean products to make; they require energy-intensive methods and increased greenhouse gas emissions as compared with steels. They are, however, clean to use, in particular in the transportation sector, if adequate weight savings and consequent fuel consumption reduction and CO2 reduction can be achieved to offset the initial higher energy need. In order to reduce CO2 emissions, better energy efficiency and substitution of low-carbon technologies are going to play a key role in future technical options. Modern research and development should be focused on promoting the efficient use of metallic materials according to the “dematerialization” concept design.
Zagloel, Teuku Yuri M.; Hakim, Inaki Maulida; Krisnawardhani, Rike Adyartie
Reverse logistics is a part of supply chain that bring materials from consumers back to manufacturer in order to gain added value or do a proper disposal. Nowadays, most companies are still facing several problems on reverse logistics implementation which leads to high waste along reverse logistics processes. In order to overcome this problem, Madsen [Framework for Reverse Lean Logistics to Enable Green Manufacturing, Eco Design 2009: 6th International Symposium on Environmentally Conscious Design and Inverse Manufacturing, Sapporo, 2009] has developed a lean reverse logistics framework as a step to eliminate waste by implementing lean on reverse logistics. However, the resulted framework sets aside criteria used to evaluate its performance. This research aims to determine weighted criteria that can be used as a base on reverse logistics evaluation by considering lean principles. The resulted criteria will ensure reverse logistics are kept off from waste, thus implemented efficiently. Analytical Network Process (ANP) is used in this research to determine the weighted criteria. The result shows that criteria used for evaluation lean reverse logistics are Innovation and Learning (35%), Economic (30%), Process Flow Management (14%), Customer Relationship Management (13%), Environment (6%), and Social (2%).
Rayra Rodrigues Nogueira
Full Text Available Due to fierce competition from companies in achieving larger market share, there is an increasing interest regarding cost reduction, efficiency in business and processes, increase in quality and continuous improvement. Given these situations, companies are adopting some practices which seek to improve their strategies, increase understanding of the needs of their customers and promote business growth, the Lean Manufacturing and Six Sigma programs were adopted in order to enable businesses to succeed in achieving continuous improvement in their business. This paper presents a case study of a textile yarn industry which, in order to increase the sales of the business and the elimination of waste, used the methodology of Lean Six Sigma Program based on DMAIC method to assist in achieving these goals.
Chiarini, Andrea; Baccarani, Claudio
Purpose This paper aims to contribute to the debate concerning total quality management (TQM)-Lean strategy in public healthcare by analyzing the deployment path for implementation, the possible benefits that can be achieved and the encountered pitfalls. Design/methodology/approach Three case studies are drawn from three large Italian hospitals with more than 500 beds each and structured with many departments. The hospitals are located in Tuscany, Italy. These three hospitals have embraced TQM and Lean, starting from strategic objectives and their deployment. At the same time, they have also implemented many TQM-Lean tools. The case studies are based on interviews held with four managers in each of these three public hospitals. Findings Results from the interviews show that there is a specific deployment path for TQM-Lean implementation. The hospitals have also achieved benefits linked to patient satisfaction and improved organizational performances. Problems related to organizational and cultural issues, such as senior managers' commitment, staff management, manufacturing culture and tools adaptation, could affect the benefits. Research limitations/implications The research has been carried out in just three Italian public hospitals. Hence, similar investigations could be managed in other countries. Researchers could also use a larger sample and investigate these issues by means of quantitative inquiry. Practical implications Practitioners could try to apply the deployment path revealed by these case studies in other public and private hospitals. Originality/value The results of this research show that there is a specific, new deployment path for implementing TQM-Lean strategy in some public hospitals.
Full Text Available Competitive advantage now increasingly rests upon a dynamic capability to compete successfully in an environment of frequent, challenging and unpredictable change. The agile manufacturing a recently popularized concept has been advocated as the 21st century manufacturing paradigm. In adopting and developing the key elements of agile manufactruring, there is requirement for enterprises to overcome the philosophical challenges of a shift from mass/lean production to the customization of agility. Beside that, enterprises should explore the key success factors to support succesfull agile implementation.
Liker, Jeffrey K; Lamb, Thomas
.... Through years of trial and error on the shopfloor Toyota discovered that they could simultaneously achieve high quality, low cost, and just-in time delivery by shortening the production flow by eliminating waste...
Arezes, Pedro M; Dinis-Carvalho, José; Alves, Anabela Carvalho
Lean Production Systems (LPS) have become very popular among manufacturing industries, services and large commercial areas. A LPS must develop and consider a set of work features to bring compatibility with workplace ergonomics, namely at a muscular, cognitive and emotional demands level. Identify the most relevant impacts of the adoption of LPS from the ergonomics point of view and summarizes some possible drawbacks for workplace ergonomics due to a flawed application of the LPS. The impacts identified are focused in four dimensions: work pace, intensity and load; worker motivation, satisfaction and stress; autonomy and participation; and health outcome. This paper also discusses the influence that the work organization model has on workplace ergonomics and on the waste elimination previewed by LPS. Literature review focused LPS and its impact on occupational ergonomics conditions, as well as on the Health and Safety of workers. The main focus of this research is on LPS implementations in industrial environments and mainly in manufacturing industry workplaces. This is followed by a discussion including the authors' experience (and previous research). From the reviewed literature it seems that there is no consensus on how Lean principles affect the workplace ergonomics since most authors found positive (advantages) and negative (disadvantages) impacts. The negative impacts or disadvantages of LPS implementations reviewed may result from the misunderstanding of the Lean principles. Possibly, they also happen due to partial Lean implementations (when only one or two tools were implemented) that may be effective in a specific work context but not suitable to all possible situations as the principles of LPS should not lead, by definition, to any of the reported drawbacks in terms of workplace ergonomics.
Abernathy, F H; Dunlop, J T; Hammond, J H; Weil, D
As retailers adopt lean retailing practices, manufacturers are feeling the pinch. Retailers no longer place large seasonal orders for goods in advance-instead, they require ongoing replenishment of stock, forcing manufacturers to predict demand and then hold substantial inventories indefinitely. Manufacturers now carry the cost of inventory risk--the possibility that demand will dry up and goods will have to be sold below cost. And as product proliferation increases, customer demand becomes harder to predict. Most manufacturers apply one inventory policy for all stock-keeping units in a product line. But the inventory demand for SKUs within the same product line can vary significantly. SKUs with high volume typically have little variation in weekly sales, while slow-selling SKUs can vary enormously in weekly sales. The greater the variation, the larger the inventory the manufacturer must hold relative to an SKU's expected weekly sales. By differentiating inventory policies at the SKU level, manufacturers can reduce inventories for the high-volume SKUs and increase them for the low-volume ones--and thereby improve the profit-ability of the entire line. SKU-level differentiation can also be applied to sourcing strategies. Instead of producing all the SKUs for a product line at a single location, either offshore at low cost or close to market at higher cost, manufacturers can typically do better by going for a mixed allocation. Low-variation goods should be produced mainly offshore, while high-variation goods are best made close to markets.
National Aeronautics and Space Administration — The Advanced Manufacturing Technologies (AMT) Project supports multiple activities within the Administration's National Manufacturing Initiative. A key component of...
Wright, John R.
Lean manufacturing, a streamlined system of flow and job shop techniques, relies on self-directed work teams. Technology educators can prepare students for work in this environment by using problem-solving teams in the classroom to work on design briefs and other group projects. (SK)
Full Text Available Artiklen følger tre lærere, der alle har set sig nødsaget til at revidere den lærergerning, de havde forberedt sig til. Deres møde med lokale og centrale styringsformer af skolen har begrænset anvendelsen af deres erhvervede kundskaber i et sådant omfang, at de enten har måttet revidere deres væren i erhvervet eller helt forlade det. De tre cases bearbejdes med udgangspunkt i de spændinger mellem individ og institution som E. Goffman og P. Bourdieu har undersøgt som tilpasnings- og modstandsformer. Artiklen behandler disse to spørgsmål: Under hvilke sociale betingelser bliver den hengivne identifikation med lærererhvervet til, hvad betinger ’ildsjælens’ investeringer i sit arbejde? Og hvad sker der med lærerens selvforståelse, når rummet for mulige mod standsformer svinder ind?Nøgleord: Lærer; modstand; afprofessionalisering; Goffman; BourdieuAbstractThe article follows three teachers, who have all felt pressured to revise the professional life they all had prepared for. Their encounters with local and central legal authorities responsible for school administration seem to have limited the exercise of their acquired skills to such an extent that they either have had to consider whether they are to remain in the profession or simply leave it. The three cases are analysed with focus on the tension involved in being an individual in an institutional setting. Contradictions of assimilation and resistance in the teachers’ lives are handled using the theoretical frameworks of E. Goffman and P. Bourdieu. The article deals with two questions: What kind of social conditions promote the devoted and highly enthusiastic professional teacher? And what happens to the teachers’ self-recognition when the scope of possible forms of resistance becomes restricted? Keywords: Teacher; resistance; deprofessionalization; Goffman; Bourdieu
Kemper, B.; de Mast, J.
Lean Six Sigma is an advanced process improvement methodology. Initially, Six Sigma focused on the reduction of the number of defects in manufacturing. It was introduced at Motorola in 1986, and it incorporates previous methodologies, such as Statistical Process Control, Total Quality Management,
Pool, Arnout; Wijngaard, Jacob; van der Zee, D.J.
The lean approach is an idealizing improvement approach that has an enormous impact in the field of operations management. It started in the automotive industry and has since been widely applied in discrete manufacturing. However, extensions to the (semi-) process industry have been much slower.
Full Text Available Purpose: This paper describes a typical Value stream mapping (VSM application enhanced by the discrete event simulation (DES to a dedicated tubular manufacturing process. Design/Methodology/Approach: VSM is prescribed as part of lean production portfolio of tools, not only highlights process inefficiencies, transactional and communication mismatches, but also guides improvement areas. Meanwhile, DES is used to reduce uncertainty and create consensus by visualizing dynamic process views. It is served as a complementary tool for the traditional VSM to provide sufficient justification and quantifiable evidence needed to convince the lean approaches. A simulation model is developed to replicate the operation of an existing system, and that of a proposed system that modifies the existing design to incorporate lean manufacturing shop floor principles. Findings: A comprehensive model for the tubular manufacturing process is constructed, and distinctive scenarios are derived to uncover an optimal future state of the process. Various simulation scenarios are developed. The simulated results are acquired and investigated, and they are well matched with the real production data. Originality/Value: DES is demonstrated as a guided tool to assist organizations with the decision to implement lean approaches by quantifying benefits from applying the VSM. A roadmap is provided to illustrate how the VSM is used to design a desired future state. The developed simulation scenarios mimic the behavior of the actual manufacturing process in an intuitive manner.
Hilton, Roger John
Over the last two decades, manufacturers in Australia have implemented process improvement methodologies to assist in driving down the costs of operations brought on by customers wanting better quality and responsiveness. Closely following in the footsteps of the manufacturers, since the early 2000’s, are service organizations, including those in Healthcare, Finance/Banking, IT and Government (Public sector). Lean Six Sigma is one such process improvement methodology. It is seen as the lat...
Lippke, Lena; Tanggaard, Lene
Over the last few decades, qualitative research has been acknowledged as a peopled practice in which subjectivities come into play. The main argument presented in this article is that qualitative research involves “muddy,” troublesome, interactional passages, because of a complex interplay between...... situated identities among the participants cross each other. We emphasize the value of daring to lean in to the muddiness of peopled research, use it as an analytical tool and present it in its imperfect form. This approach contributes to transparency in qualitative research, opens up the data in a new way...... subjectivities, situated identities, emotions, and conversational genres. Based on ethnographic fieldwork at a Danish Vocational Educational Training College, we introduce the concept of “leaning in” to provide an analytical grasp of the “muddy” interactional tension field in an interview situation, in which...
de Koning, Henk; Verver, John P S; van den Heuvel, Jaap; Bisgaard, Soren; Does, Ronald J M M
Healthcare, as with any other service operation, requires systematic innovation efforts to remain competitive, cost efficient, and up-to-date. This article outlines a methodology and presents examples to illustrate how principles of Lean Thinking and Six Sigma can be combined to provide an effective framework for producing systematic innovation efforts in healthcare. Controlling healthcare cost increases, improving quality, and providing better healthcare are some of the benefits of this approach.
Alexandra Mirela Cristina MUNTEANU
Full Text Available This paper analyzes the benefits of Lean Six Sigma in comparison with Lean and Six Sigma, traditional improvement methodologies. The introduction highlights the appearance of Lean Six Sigma, early 2000s, as well as the benefits brought by the integrated approach. The following parts of the study emphasize the main differences between methodologies and their commonalities based on their synergy. Finally the advantages of Lean Six Sigma versus Lean and Six Sigma are analyzed and systematized by author in order to reveal Lean Six Sigma’s benefits.
Full Text Available Current industrial production is driven by increasing globalization, which has led to a steady increase in production volumes and complexity of products aimed at the pursuit of meeting the needs of customers. In this context, one of the main tools in the management of customer value is Lean Manufacturing or Production, though it is considered primarily as a set of tools to reduce the total cost of the resources needed to achieve such needs. This philosophy has recently been enriched in the literature with case studies that link Lean Management (LM with the improvement of environmental sustainability. The consequence is an expansion of the Computer Integrated Manufacturing (CIM; indeed, CIM, currently, combining and integrating the key business functions (e.g., business, engineering, manufacturing, and information management with a view of the life cycle, does not highlight the strategic role of the environmental aspects. In order to deal with the increasingly rapid environmental degradation that is reflected in society, in terms of both economy and quality of life, Industrial Ecology (IE introduced a new paradigm of principles and instruments of analysis and decision support (e.g., Life Cycle Assessment—LCA, Social Life Cycle Assessment -SLCA, Material Flow Account—MFA, etc. that can be considered as the main basis for integrating the environmental aspects in each strategy, design, production, final product, and end of life management, through the re-engineering of processes and activities towards the development of an eco-industrial system. This paper presents the preliminary observations based on a analysis of both theories (LM-IE and provides a possible assessment of the key factors relevant to their integration in a “lean environmental management”, highlighting both positives (lights and possible barriers (shadows.
Hamalainen, Markko; Karjalainen, Jesse
New business models harnessing the power of individuals have already revolutionized service industries and digital content production. In this study, we investigate whether a similar phenomenon is taking place in manufacturing industries. We start by conceptually defining two distinct forms of firm-individual collaboration in manufacturing industries: (1) social cloud manufacturing, in which firms outsource manufacturing to individuals, and (2) social platform manufacturing, in which firms pr...
López Gonzalo, Cyrille
El objetivo final de este proyecto fue analizar y mejorar el funcionamiento de dos islotes de un taller mediante una metodología lean. El lean manufacturing es una cosa nueva en este taller. Antes de este proyecto, sólo se había estudiado un islote con esta metodología. Así, este proyecto fue la oportunidad de implementar técnicas de lean manufacturing en dos islotes más. En este caso, decidimos emplear la metodología DMAIC para desarrollar este proyecto. Así, podíamos organizar ...
Priyaadarshini, R. G.; Sathish Kumar, V. R.; Aishwarya Rajlakshmi, S.
In the era of stiff competition and customer expectations, manufacturing organizations across the world are struggling hard to minimize their costs and maximise their performance. Micro, Small and Medium enterprises (MSMEs), who are dependent on large corporate for business and support have a tall task of keeping pace quality in processes and output. They are in the constant vigil to adopt new systems and practices so that they can minimise their cost and maximize the productivity. This study has been conducted in the machine tool sector of Coimbatore, India; which houses more than 9000 companies and offers employment to over one lakh employees. They have a tremendous pressure to use scientific processes to increase their product quality and productivity. While Lean manufacturing has been the thrust to improve the competitiveness among MSMEs in India, this study has attempted to understand their attitude towards lean management and understand the extent to which companies practice lean tools and practices. It has been found that most of the organizations in the study possess a culture of lean thinking and possess the support of top management and employees also towards the initiative. It is also seen that the organizations that incorporated lean in their daily operations have been able to scale up their productivity.
Full Text Available Lean manufacturing is an applied methodology of scientific, objective techniques that cause work tasks in a process to be performed with a minimum of non-value adding activities resulting in greatly reduced wait time, queue time, move time, administrative time, and other delays. This work addresses the implementation of lean principles in a construction equipment company. The prime objective is to evolve and test several strategies to eliminate waste on the shop floor. This paper describes an application of value stream mapping (VSM. Consequently, the present and future states of value stream maps are constructed to improve the production process by identifying waste and its sources. A noticeable reduction in cycle time and increase in cycle efficiency is confirmed. The production flow was optimized thus minimizing several non-value added activities/times such as bottlenecking time, waiting time, material handling time, etc. This case study can be useful in developing a more generic approach to design lean environment.
Full Text Available Kjeld Harald Aij, Sofia Rapsaniotis VU University Medical Center, Division Acute Care and Surgery, Amsterdam, The Netherlands Abstract: As health care organizations face pressures to improve quality and efficiency while reducing costs, leaders are adopting management techniques and tools used in manufacturing and other industries, especially Lean. Successful Lean leaders appear to use a coaching leadership style that shares underlying principles with servant leadership. There is little information about specific similarities and differences between Lean and servant leaderships. We systematically reviewed the literature on Lean leadership, servant leadership, and health care and performed a comparative analysis of attributes using Russell and Stone’s leadership framework. We found significant overlap between the two leadership styles, although there were notable differences in origins, philosophy, characteristics and behaviors, and tools. We conclude that both Lean and servant leaderships are promising models that can contribute to the delivery of patient-centered, high-value care. Servant leadership may provide the means to engage and develop employees to become successful Lean leaders in health care organizations. Keywords: management, leadership attributes, efficiency, patient-centered, high-value care
Roghanian, E.; Alipour, Mohammad
Lean production has become an integral part of the manufacturing landscape as its link with superior performance and its ability to provide competitive advantage is well accepted among academics and practitioners. Lean production helps producers in overcoming the challenges organizations face through using powerful tools and enablers. However, most companies are faced with restricted resources such as financial and human resources, time, etc., in using these enablers, and are not capable of implementing all these techniques. Therefore, identifying and selecting the most appropriate and efficient tool can be a significant challenge for many companies. Hence, this literature seeks to combine competitive advantages, lean attributes, and lean enablers to determine the most appropriate enablers for improvement of lean attributes. Quality function deployment in fuzzy environment and house of quality matrix are implemented. Throughout the methodology, fuzzy logic is the basis for translating linguistic judgments required for the relationships and correlation matrix to numerical values. Moreover, for final ranking of lean enablers, a multi-criteria decision-making method (PROMETHEE) is adopted. Finally, a case study in automotive industry is presented to illustrate the implementation of the proposed methodology.
Schweikhart, Sharon A; Dembe, Allard E
Lean and Six Sigma are business management strategies commonly used in production industries to improve process efficiency and quality. During the past decade, these process improvement techniques increasingly have been applied outside the manufacturing sector, for example, in health care and in software development. This article concerns the potential use of Lean and Six Sigma in improving the processes involved in clinical and translational research. Improving quality, avoiding delays and errors, and speeding up the time to implementation of biomedical discoveries are prime objectives of the National Institutes of Health (NIH) Roadmap for Medical Research and the NIH's Clinical and Translational Science Award program. This article presents a description of the main principles, practices, and methods used in Lean and Six Sigma. Available literature involving applications of Lean and Six Sigma to health care, laboratory science, and clinical and translational research is reviewed. Specific issues concerning the use of these techniques in different phases of translational research are identified. Examples of Lean and Six Sigma applications that are being planned at a current Clinical and Translational Science Award site are provided, which could potentially be replicated elsewhere. We describe how different process improvement approaches are best adapted for particular translational research phases. Lean and Six Sigma process improvement methods are well suited to help achieve NIH's goal of making clinical and translational research more efficient and cost-effective, enhancing the quality of the research, and facilitating the successful adoption of biomedical research findings into practice.
Liana, N. A.; Amsyar, N.; Hilmy, I.; Yusof, MD
The industrial sector in Malaysia is one of the main sectors that have high percentage of energy demand compared to other sector and this problem may lead to the future power shortage and increasing the production cost of a company. Suitable initiatives should be implemented by the industrial sectors to solve the issues such as by improving the machining system. In the past, the majority of the energy consumption in industry focus on lighting, HVAC and office section usage. Future trend, manufacturing process is also considered to be included in the energy analysis. A study on Lean Energy Analysis in a machining process is presented. Improving the energy efficiency in a lathe machine by enhancing the cutting parameters of turning process is discussed. Energy consumption of a lathe machine was analyzed in order to identify the effect of cutting parameters towards energy consumption. It was found that the combination of parameters for third run (spindle speed: 1065 rpm, depth of cut: 1.5 mm, feed rate: 0.3 mm/rev) was the most preferred and ideal to be used during the turning machining process as it consumed less energy usage.
Full Text Available Lean principles and methods, originating in a Japanese cultural context, have spread to a large number of companies throughout the world. The aim of this case study research is to identify and compare national cultural aspects that influence Lean Production and Lean Product Development implementation in Swedish companies. Data were collected through questionnaires, interviews and an industrial workshop with Swedish Lean practitioners. The study shows that some sub-areas in Lean, such as value definition, control systems, leadership, team development, knowledge management, and strategies, are highly dependent on contextual factors related to human, cultural and organizational aspects. These are related to the national culture and should be considered to a higher extent for successful sustainable implementation of Lean in different cultural contexts. As for implementing Lean in Sweden, national cultural characteristics, such as individualism, autonomy and supportive management style fit well with Lean thinking.
The aim of this thesis is to enhance the management of supply systems in construction industry using lean principles. This study is an attempt to identify what kind of activities causes’ construction process delay and how to perform lean concept into supply chain in practice. The objective is to assure on-time delivery of information and materials to construction sites at lowest cost and maximum value for the customer. These study problems have been analysed from a lean construction supply ch...
Pham Ngoc, Lan
The purpose of this thesis was to study the effects of Lean Thinking in Project Management and how applying Lean Project Management could enhance the productivity of project work. The study was carried using theoretical research and collecting empirical data from three interviews and one case study at a local company. At the end of the study, the major project management problems at the company were identified and analyzed following Lean Principles. It was also pointed out where there...
de Koning, H.; Does, R.J.M.M.; Bisgaard, S.
Lean Thinking and Six Sigma are typically considered as separate approaches to process innovation, with complementary strengths. When combined as Lean Six Sigma, this approach provides a unified framework for systematically developing innovations. Lean Six Sigma can also bring about significant results and breakthrough improvements in financial services, as demonstrated with four case studies from Dutch multinational insurance companies. These cases demonstrate the importance of incremental i...
Thirstrup, Janne Pia; Jensen, Just; Meier, Kristian
Selektion for høj pelskvalitet og store skind foregår i praksis på levende dyr, mens prisen for skindet vurderes efter pelsning. Vores analyser viste positiv men lav korrelation mellem pelskvalitetsegenskaber vurderet på henholdsvis levende dyr og skind. Ydermere fandt vi en negativ korrelation...
Nielsen, Steffen Larni; Madsen, Bjarke
Invasive arter blandt andre Japansk Pileurt, Kæmpe Pileurt og Rynket Rose, har Aarhus Kommune et særligt fokus på. Vi undersøgte floristiske forskelle mellem lokaliteter med og uden de nævnte invasive plantearter. Vi fandt, at artsrigdom og naturværdi er lavere, samt en anderledes artssammensætning...
Jensen, Per Langaa
Lean has for the last decade developed as the dominating model for developing productions processes not only within industry but also in health care, administration and service industries in general. With this development a discussion on human factors aspects of lean has developed internationally....... Literature studies documents that it is not possible to establish a clear relation between lean and the psychosocial aspects of work. The studies also indicate that the context and the implementations process play a dominating role in how lean is experienced. This has been the basis for establishing...
Flumerfelt, Shannon; Kahlen, Franz-Josef
This edited volume presents a structured approach to a new lean education curriculum, implemented for the education of engineers, managers, administrators as well as human resources developers. The authorship comprises professors and lecturers, trainers and practitioners who educate future professionals in Lean Thinking principles and tools. This edited book provides a platform for authors to share their efforts in building a Body of Knowledge (BoK) for Lean Education. The topical spectrum is state-of-the-art in this field, but the book also includes a glimpse into future developments. This is a highly informative and carefully presented book, providing valuable insight for scholars with an interest in Lean Education.
De Zan, Giovanni; De Toni, Alberto Felice; Fornasier, Andrea; Battistella, Cinzia
Purpose: The purpose of this paper is to present a methodology to assess the experiential learning processes of learning lean in an innovative learning environment: the lean model factories. Design/methodology/approach: A literature review on learning and lean management literatures was carried out to design the methodology. Then, a case study…
Suetina Tatiana Aleksandrovna
Full Text Available This article is about methods and ways of providing changes on enterprices which introduce instruments of lean production. The main accent is how to use metodology of the project management by providing lean-changes. Lean program is proposed as a program of strategic developement of enterprices.
Van Demark, Robert E; Smith, Vanessa J S; Fiegen, Anthony
Health care in the United States is both expensive and wasteful. The cost of health care in the United States continues to increase every year. Health care spending for 2016 is estimated at $3.35 trillion. Per capita spending ($10,345 per person) is more than twice the average of other developed countries. The United States also leads the world in solid waste production (624,700 metric tons of waste in 2011). The health care industry is second only to the food industry in annual waste production. Each year, health care facilities in the United States produce 4 billion pounds of waste (660 tons per day), with as much as 70%, or around 2.8 billion pounds, produced directly by operating rooms. Waste disposal also accounts for up to 20% of a hospital's annual environmental services budget. Since 1992, waste production by hospitals has increased annually by a rate of at least 15%, due in part to the increased usage of disposables. Reduction in operating room waste would decrease both health care costs and potential environmental hazards. In 2015, the American Association for Hand Surgery along with the American Society for Surgery of the Hand, American Society for Peripheral Nerve Surgery, and the American Society of Reconstructive Microsurgery began the "Lean and Green" surgery project to reduce the amount of waste generated by hand surgery. We recently began our own "Lean and Green" project in our institution. Using "minor field sterility" surgical principles and Wide Awake Local Anesthesia No Tourniquet (WALANT), both surgical costs and surgical waste were decreased while maintaining patient safety and satisfaction. As the current reimbursement model changes from quantity to quality, "Lean and Green" surgery will play a role in the future health care system. Copyright © 2018 American Society for Surgery of the Hand. Published by Elsevier Inc. All rights reserved.
Filipe Marafon de Paoli
Full Text Available The concepts and practices of lean manufacturing have been used by companies to obtain improvements in the efficiency levels of their manufacturing facilities. However, waste in manufacturing firms is not limited to the production floor; it is also present in administrative areas. Hence, the objective of this paper was to verify if Lean Office concepts can be applied in engineering and in the development of projects of companies with Engineer-to-Order (ETO production systems. To achieve this, an action research inquiry was carried out in a heavy equipment manufacturing firm that follows ETO principles. The selected non-manufacturing area was the Hydraulic Systems Engineering Department. As a result of this research, it was possible to verify that the principles of the Lean Office applied to the engineering and development of products in the company operating in an ETO environment can be effectively used, eliminating several types of waste existing in that area.
Full Text Available The manufacturing industry of South Africa is the sector consuming the largest portion of the total energy consumption and second largest portion of total water consumption per annum nationally. With a significant increase in electrical energy cost in recent years, together with the reserve energy margin dropping below the minimum level required for sustainable operation of energy utilities, energy efficiency improvement is becoming imperative for organisational success as well as national economical sustainability. This paper explores selected Lean manufacturing principles and its positive effect on energy and water efficiency. Although the implementation of Lean manufacturing techniques naturally leads to the improvement of energy and water intensity, the author believes that there is even greater potential in the development of a Lean based tool which will specifically focus on the improvement of energy and water efficiency. For this purpose the value stream mapping tool was chosen as the foundation. This paper continues to explain the process undergone to develop standardised energy and water specific waste categories to be used in conjunction with the traditional Lean wastes. The study concludes by detailing the development of the tool, together with its framework for implementation and a brief discussion on the forecasting model incorporated.
RADDAM , Chahida; Boumane , Abderrazak; Kamach , Oulaid
International audience; Dans une perspective de développement durable et pérenne, l'optimisation des ressources de l'entreprise suscite un intérêt considérable. Dans ce sens s'inscrit parfaitement l'approche Lean qui a conquis différents secteurs économiques en se ce positionnant comme un concept inéluctable pour améliorer la performance de l'entreprise. Par ailleurs, si Lean manufacturing est une approche bien connue et traité dans divers travaux de recherches, peu de travaux ont fait de l'a...
Weller, Harold N; Nirschl, David S; Paulson, James L; Hoffman, Steven L; Bullock, William H
The use of standardized lean manufacturing principles to improve drug discovery productivity is often thought to be at odds with fostering innovation. This manuscript describes how selective implementation of a lean optimized process, in this case centralized purification for medicinal chemistry, can improve operational productivity and increase scientist time available for innovation. A description of the centralized purification process is provided along with both operational and impact (productivity) metrics, which indicate lower cost, higher output, and presumably more free time for innovation as a result of the process changes described.
Ratner, Helene Gad; Bojesen, Anders; Bramming, Pia
turnover. This is analysed in terms of Italo Calvino's Invisible cities. It is argued that Calvino's themes and prose help us understand change as a multiplicity of temporal intensities producing ambivalence and affect. We describe this use of literary abstractions as a ‘hyperbolic social epistemology......’. Through the depiction of four intensifications of Lean Production, the metaphors of Calvino's cities show how reality and illusion; hope and poverty; dreams and death and utopia and dystopia are intricately mingled and produce temporary and equally ambivalent affects of alienation, hypocrisy, self...
Bilberg, Arne; Hadar, Ronen
Companies have to be innovative in the trinity of product development, manufacturing systems, and business, however; the weak link in this trinity seems to be manufacturing systems. Researchers and industry have seen a contradiction between LEAN and automation. The hypothesis in this research...... is that the right combination of LEAN and Automation can be a very competitive solution that combines the flexibility of human operators with the high precision, productivity, and endurance of automation by e.g. robotics. The manufacturing equipment has to be adaptable and reconfigurable to new situations. The key...... words are simplification, effectiveness and user-friendliness at the shop floor. This concept is based on simple and adaptable hybrid solutions which the authors believe can be the right solution to also handle the increasing complexity .A new order management concept has been introduced, where skilled...
nature of manufacturing systems, this law offers a tool for selecting the smallest, that is, lean, finished goods buffering, which is necessary and sufficient to ensure the desired level ofcustomer demand satisfaction.
Jordan, Lee P.; Young, Yancy; Rice, Amanda
It is recognized that payload development and integration with the International Space Station (ISS) can be complex. This streamlined integration approach is a first step toward simplifying payload integration; making it easier to fly payloads on ISS, thereby increasing feasibility and interest for more research and commercial organizations to sponsor ISS payloads and take advantage of the ISS as a National Laboratory asset. The streamlined integration approach was addressed from the perspective of highly likely initial payload types to evolve from the National Lab Pathfinder program. Payloads to be accommodated by the Expedite the Processing of Experiments for Space Station (EXPRESS) Racks and Microgravity Sciences Glovebox (MSG) pressurized facilities have been addressed. It is hoped that the streamlined principles applied to these types of payloads will be analyzed and implemented in the future for other host facilities as well as unpressurized payloads to be accommodated by the EXPRESS Logistics Carrier (ELC). Further, a payload does not have to be classified as a National Lab payload in order to be processed according to the lean payload integration process; any payload that meets certain criteria can follow the lean payload integration process.
Balmer, Christian; Michelsen, Aage U
I artiklen beskrives, hvorledes lean-principper er indført i en forsikringsvirksomhed samt de opnåede resultater.......I artiklen beskrives, hvorledes lean-principper er indført i en forsikringsvirksomhed samt de opnåede resultater....
Lean production systems use teams instead of functional departments as well as simple shop floor control methods to manage the flow of orders at the shop floor. Lean shop floor control focuses on robust and visual methods that are able to cope with variation in processing times, routing sequences,
Does, R.J.M.M.; de Koning, H.
Zowel Lean als Six Sigma zijn benaderingen van kwaliteits- en efficiëntieverbetering die op dit moment sterk in de belangstelling staan van zowel de industrie als de dienstverlening. Lean Six Sigma integreert beide benaderingen. Ze wordt door sommigen gezien als panacee voor alle mogelijke
Yasukawa, Keiko; Brown, Tony; Black, Stephen
Purpose: The purpose of this paper is to explore the possibilities for expansive learning during organisational change. It considers the introduction of "lean production" as a disturbance to the existing work practices. Design/methodology/approach: The paper considers two case studies of "lean production" training with…
van den Heuvel, J.; Does, R.J.M.M.; de Koning, H.
Abstract Hospitals today face major challenges. Patients demand quality of care to be improved continuously. Health insurance companies demand the lowest possible prices. Lean Six Sigma is a program that can help healthcare providers to achieve these (seemingly) conflicting goals. Lean Six Sigma is
Today there is a high demand for high-precision products. The manufacturing processes are now highly sophisticated and derive from a specialized genre called precision engineering. Precision Manufacturing provides an introduction to precision engineering and manufacturing with an emphasis on the design and performance of precision machines and machine tools, metrology, tooling elements, machine structures, sources of error, precision machining processes and precision process planning. As well as discussing the critical role precision machine design for manufacturing has had in technological developments over the last few hundred years. In addition, the influence of sustainable manufacturing requirements in precision processes is introduced. Drawing upon years of practical experience and using numerous examples and illustrative applications, David Dornfeld and Dae-Eun Lee cover precision manufacturing as it applies to: The importance of measurement and metrology in the context of Precision Manufacturing. Th...
Hansen, Nanette Juhler
rationalization strategies, among others Lean, claim to improve working conditions. The aim of this thesis is to identify whether the application of Lean strategies leads to a reduction of the occupational health and safety problem repetitive work. Repetitive work is a problem created by the Taylorisation of work......, and therefore it is to be expected that a break with one or more of the Tayloristic principles can lead to a reduction of repetitive work. This thesis points out a number of areas within which Lean breaks with Tayloristic principles, whilst other principles are maintained. These breaks between Lean...... and Taylorism are also found in the study of the case company. By linking breaks with Taylorism with solutions for the reduction of repetitive work, I point out a number of openings in Lean that may lead to a reduction of repetitive work. By using the concept of openings I present the possibilities offered...
Plummer, Hillary A; Oliver, Gretchen D; Powers, Christopher M; Michener, Lori A
Impaired trunk motion during pitching may be a risk factor for upper extremity injuries. Specifically, increased forces about the shoulder and elbow have been observed in pitchers with excessive contralateral trunk lean during pitching. Because of the difficulty in identifying abnormal trunk motions during a high-speed task such as pitching, a clinical screening test is needed to identify pitchers who have impaired trunk motion during pitching. The purpose of this study was to determine the relationship between the degree of lateral trunk lean during the single-leg squat and amount of trunk lean during pitching and if trunk lean during pitching can be predicted from lean during the single-leg squat. Controlled Laboratory Study; Cross-sectional. Seventy-three young baseball pitchers (11.4 ± 1.7 years; 156.3 ± 11.9 cm; 50.5 ± 8.8 kg) participated. An electromagnetic tracking system was used to obtain trunk kinematic data during a single-leg squat task (lead leg) and at maximum shoulder external rotation of a fastball pitch. Pearson correlation coefficients for trunk lean during the single-leg squat and pitching were calculated. A linear regression analysis was performed to determine if trunk lean during pitching can be predicted from lean during the single-leg squat. There was a positive correlation between trunk lean during the single-leg squat and trunk lean during pitching (r = 0.53; plean during the single-leg squat predicted the amount of lateral trunk lean during pitching (R 2 = 0.28; p lean during an SLS and pitching. Trunk lean during the single-leg squat explained 28% of the variance in trunk lean during pitching. Diagnosis, level 3.
Duarte, Susana Carla Vieira Lino Medina
The success of an organization depends on the effective control of its supply chain. It is important to recognize new opportunities for organization and its supply chain. In the last few years the approach to lean, agile, resilient and green supply chain paradigms has been addressed in the scientific literature. Research in this field shows that the integration of these concepts revealed some contradictions among so many paradigms. This thesis is mainly focused on the lean and green approaches. Thirteen different management frameworks, embodied in awards, standards and tools were studied to understand if they could contribute for the modelling process of a lean and green approach. The study reveals a number of categories that are common in most management frameworks, providing adequate conditions for a lean and green supply chain transformation. A conceptual framework for the evaluation of a lean and green organization`s supply chain was proposed. The framework considers six key criteria, namely, leadership, people, strategic planning, stakeholders, processes and results. It was proposed an assessment method considering a criteria score for each criterion. The purpose is to understand how lean and green supply chain can be compatible, using principles, practices, techniques or tools (i.e. elements) that support both, a lean and a green approach, in all key criteria. A case study in the automotive upstream supply chain was performed to understand more deeply if the elements proposed for the conceptual framework could be implemented in a real-scenario. Based on the conceptual framework and the case study, a roadmap to achieve a lean-green transformation is presented. The proposed roadmap revealed its contribution to the understanding on how and when an organization`s supply chain should apply the lean and green elements. This study is relevant to practice, as it may assist managers in the adoption of a lean and green supply chain approach, giving insights for the
Full Text Available In this article, we discuss important aspects of the perceived problematic relationship between self-management and standardization. The article presents data from three case studies conducted within manufacturing companies in Sweden, where the popularity of lean production has led to a renaissance for short-cycle and standardized assembly work in settings that traditionally have made use of sociotechnical production design. The data suggest that the implementation has not contributed to an increased commitment, smooth operations, and capacity for change and innovation. Despite these not so positive results, it is argued that it is possible to combine self-management principles with lean production and standardization if 1 the implementation of lean is done with a contextual sensitivity, 2 a balance is reached between the use of standards on the one hand and work enrichment on the other, and 3 a feeling of ownership as regards both implementation and production process is upheld among the product on personnel.
During the process of facility planning, Fairview Laboratory Services utilized LEAN manufacturing to maximize efficiency, simplify processes, and improve laboratory support of patient care services. By incorporating the LEAN program's concepts in our pilot program, we were able to reduce turnaround time by 50%, improve productivity by greater than 40%, reduce costs by 31%, save more than 440 square feet of space, standardize work practices, reduce errors and error potential, continuously measure performance, eliminate excess unused inventory and visual noise, and cross-train 100% of staff in the core laboratory. In addition, we trained a core team of people that is available to coordinate future LEAN projects in the laboratory and other areas of the organization.
Scott William Lyon
Full Text Available The forest products industry has an opportunity to reduce energy costs using energy management practices, thereby boosting its global competitiveness. Increasing manufacturing costs have contributed significantly to the decline of the forest products manufacturing industries in the U.S.; these increasing costs limit manufacturers’ abilities to compete with their global competitors. U.S. companies are continually improving their products, processes, finances, and business practices to better compete with global marketplaces; however, they may not be seizing all of the opportunities available through more efficient energy consumption practices. By eliminating non-valued added activities, lean thinking is an example of one tool that may improve performance and reduce costs. A case study was conducted at a cabinet manufacturer in Virginia to examine the impact of lean thinking on the consumption of electricity in the manufacturing process. An energy management system was used to provide rapid feedback on electrical energy consumption for production operations. Significant changes were observed after implementing energy reduction practices identified by lean thinking tools.
Buesa, René J
Histology laboratories (histolabs) can increase productivity and reduce turnaround time and errors by using any one of several available management tools. After a few years of operation, all histolabs develop workflow problems. Histology laboratories handling more than 20,000 cases per year benefit the most from implementing management tools, as occurred in the 25 facilities summarized in this article. Discontinuous workflow, lack of "pulling" between steps, accepting unavoidable waiting times while working with small batches within work cells, and a workflow with an uneven rate of completion, are some of the adaptations required by the Lean system when it is used in histology because 70% of the tasks are manual and the flow has to be interrupted to add value to the pieces of tissue during tissue processing, no matter how short that step is. After all these adaptations are incorporated, the histolab becomes as "Lean" as it can be, and the qualifier is also a recognition of the effort and personnel involvement in the implementation. Given its service nature, productivity increments do not expand the histolab customer base and could lead to staffing reductions. This is one of the causes of reluctance by some employees for implementing these techniques which are mostly driven by cost reductions sought by insurance companies and administrators, and not necessarily because of a real medical need to reduce the turnaround time. Finally, any histolab wanting to improve its workflow can follow some easy steps presented here as a guide to accomplish that objective. These steps stress the need for the supervisors to insure that the personnel in the histology laboratory are being paid at a comparable rate as other histolabs in the area.
Moraros, John; Lemstra, Mark; Nwankwo, Chijioke
Lean is a widely used quality improvement methodology initially developed and used in the automotive and manufacturing industries but recently expanded to the healthcare sector. This systematic literature review seeks to independently assess the effect of Lean or Lean interventions on worker and patient satisfaction, health and process outcomes, and financial costs. We conducted a systematic literature review of Medline, PubMed, Cochrane Library, CINAHL, Web of Science, ABI/Inform, ERIC, EMBASE and SCOPUS. Peer reviewed articles were included if they examined a Lean intervention and included quantitative data. Methodological quality was assessed using validated critical appraisal checklists. Publically available data collected by the Saskatchewan Health Quality Council and the Saskatchewan Union of Nurses were also analysed and reported separately. Data on design, methods, interventions and key outcomes were extracted and collated. Our electronic search identified 22 articles that passed methodological quality review. Among the accepted studies, 4 were exclusively concerned with health outcomes, 3 included both health and process outcomes and 15 included process outcomes. Our study found that Lean interventions have: (i) no statistically significant association with patient satisfaction and health outcomes; (ii) a negative association with financial costs and worker satisfaction and (iii) potential, yet inconsistent, benefits on process outcomes like patient flow and safety. While some may strongly believe that Lean interventions lead to quality improvements in healthcare, the evidence to date simply does not support this claim. More rigorous, higher quality and better conducted scientific research is required to definitively ascertain the impact and effectiveness of Lean in healthcare settings. © The Author 2016. Published by Oxford University Press in association with the International Society for Quality in Health Care.
Kruskal, Jonathan B; Reedy, Allen; Pascal, Laurie; Rosen, Max P; Boiselle, Phillip M
Many hospital radiology departments are adopting "lean" methods developed in automobile manufacturing to improve operational efficiency, eliminate waste, and optimize the value of their services. The lean approach, which emphasizes process analysis, has particular relevance to radiology departments, which depend on a smooth flow of patients and uninterrupted equipment function for efficient operation. However, the application of lean methods to isolated problems is not likely to improve overall efficiency or to produce a sustained improvement. Instead, the authors recommend a gradual but continuous and comprehensive "lean transformation" of work philosophy and workplace culture. Fundamental principles that must consistently be put into action to achieve such a transformation include equal involvement of and equal respect for all staff members, elimination of waste, standardization of work processes, improvement of flow in all processes, use of visual cues to communicate and inform, and use of specific tools to perform targeted data collection and analysis and to implement and guide change. Many categories of lean tools are available to facilitate these tasks: value stream mapping for visualizing the current state of a process and identifying activities that add no value; root cause analysis for determining the fundamental cause of a problem; team charters for planning, guiding, and communicating about change in a specific process; management dashboards for monitoring real-time developments; and a balanced scorecard for strategic oversight and planning in the areas of finance, customer service, internal operations, and staff development. © RSNA, 2012.
The purpose of this study was to investigate whether or not there have been successful applications of lean manufacturing principles in highly variable defense IT environments. Specifically, the study assessed if implementation of the lean philosophies by a defense organization yielded repeatable, predictable results in software release schedules reductions. Additionally, the study set out to determine what potential critical success factors (CSF's) were documented in the secondary data captured for each release, and extracted the variables used in the decision making for acceptability of fielding. In evaluating lean applicability to the high variability environment of USAF IT acquisitions, the research was conducted using non-experimental quantitative methods of archival secondary data. The sample for this case study was compiled from a USAF office that had implemented these techniques in pre-development, development and testing, and fielding phases. Based on the research data, acquisitionists and lean practitioners are inherently interconnected. Therefore, an understanding that critical success factors (CSFs) are integral to successful lean application in DoD IT acquisitions is crucial. Through a combination of synergistic alignments, plyometric CSFs were discovered to maximize the effects of each single CSF to produce rapid results in defense IT acquisitions. These include: (1) Enterprise Incorporation, (2) Team Trust, (3) Transformational Leadership, (4) Recursive Improvement, (5) Integrated Synergy, (6) Customer-Centric Culture and (7) Heuristic Communication.
Gersing, Kilian; Oehmen, Josef; Rebentisch, Eric Rebentisch
There is a large and growing body of knowledge regarding so-called Lean best practices, including most recently in the area of program management and systems engineering. However, there is little elaboration of how these documented best practices are to be introduced to a professional workforce. ...... the Lean principles. The framework was validated through interactions with training professionals in a large automobile manufacturer, and using subject matter experts from a variety of industrial sectors. © 2014 The Authors. Published by Elsevier B.V.......There is a large and growing body of knowledge regarding so-called Lean best practices, including most recently in the area of program management and systems engineering. However, there is little elaboration of how these documented best practices are to be introduced to a professional workforce...... the systematic design of workshops focused specifically on the introduction of Lean principles and practices to program management and the professional workforce in a program environment. The framework is based on a thorough review of literature on training, workshop delivery, and Lean principles, as well...
The purpose of this paper is to examine the relationship between four organizational cultural types defined by the Competing Values Framework and three Lean Six Sigma implementation components - management involvement, use of Lean Six Sigma methods and Lean Six Sigma infrastructure. The study involved surveying 446 human resource and quality managers from 223 hospitals located in Maine, New Hampshire, Vermont, Massachusetts and Rhode Island using the Organizational Culture Assessment Instrument. Findings - In total, 104 completed responses were received and analyzed using multivariate analysis of variance. Follow-up analysis of variances showed management support was significant, F(3, 100)=4.89, p cultures having significant interactions with management support. The relationship between organizational culture and Lean Six Sigma in hospitals provides information on how specific cultural characteristics impact the Lean Six Sigma initiative key components. This information assists hospital staff who are considering implementing quality initiatives by providing an understanding of what cultural values correspond to effective Lean Six Sigma implementation. Managers understanding the quality initiative cultural underpinnings, are attentive to the culture-shared values and norm's influence can utilize strategies to better implement Lean Six Sigma.
Wackerbarth, Sarah B; Strawser-Srinath, Jamie R; Conigliaro, Joseph C
Organizations use lean principles to increase quality and decrease costs. Lean projects require an understanding of systems-wide processes and utilize interdisciplinary teams. Most lean tools are straightforward, and the biggest barrier to successful implementation is often development of the team aspect of the lean approach. The purpose of this article is to share challenges experienced by a lean team charged with improving a hospital discharge process. Reflection on the experience provides an opportunity to highlight lessons from The Team Handbook by Peter Scholtes and colleagues. To improve the likelihood that process improvement initiatives, including lean projects, will be successful, organizations should consider providing training in organizational change principles and team building. The authors' lean team learned these lessons the hard way. Despite the challenges, the team successfully implemented changes throughout the organization that have had a positive impact. Training to understand the psychology of change might have decreased the resistance faced in implementing these changes. © 2014 by the American College of Medical Quality.
Full Text Available Many studies have been done to identify the critical success factors (CSFs in for successful lean implementation in the manufacturing firms. But, till date, no systematic study has been done to identify the CSFs from the perspective of lean implementation in IT support service sector. This paper aims to address this area. A detailed literature review was undertaken to identify CSFs for lean implementation in manufacturing and services context and to consider their applicability to the IT support services sector. This paper is based on a conceptual discussion of CSFs as applied to the IT support services sector. The authors proposed a set of CSFs which is believed to be suitable for IT support service enterpri ses. The relevance of CSFs will need to be tested and qualitative research is needed to inform further work. The proposed CSFs are aimed at being useful to IT support services sector as a guideline, so as to ensure a positive outcome of the lean implementation process in IT support services sector.
Fine, Benjamin A; Golden, Brian; Hannam, Rosemary; Morra, Dante
Canadian healthcare organizations are increasingly asked to do more with less, and too often this has resulted in demands on staff to simply work harder and longer. Lean methodologies, originating from Japanese industrial organizations and most notably Toyota, offer an alternative - tried and tested approaches to working smarter. Lean, with its systematic approaches to reducing waste, has found its way to Canadian healthcare organizations with promising results. This article reports on a study of five Canadian healthcare providers that have recently implemented Lean. We offer stories of success but also identify potential obstacles and ways by which they may be surmounted to provide better value for our healthcare investments.
Dette paper bygger på et casestudie af implementeringen af blended læring i to professionsuddannelser ved University College Nord i Danmark. I paperet afdækkes studerendes udfordringer i positionen mellem central styring og decentral autonomi: 1) På den ene side de ydre styringsbetingelser, og...... kompetencemål skal de studerendes opnå selvstyret læring for at kvalificere sig til kommende profession, videreuddannelse, livslang læring og professionsudvikling. Denne kvalificering kan være i risiko for at blive undergravet af den centrale styring. På baggrund heraf undersøges problemstillingen: Hvordan......, praktikken og de studerendes fremtidige professionspraksis. Det anbefales, at der arbejdes både centralt og decentralt med at minimere de studerendes dilemmaposition mellem central styring og autonomi til gavn for samfundet og brugerne af de professionelles ydelser....
Dette paper bygger på et casestudie af, hvordan blended læring implementeres i to professionsuddannelser ved University College Nord i Danmark. Denne forskning afslører studerendes udfordringer mellem central styring og decentral autonomi: 1) På den ene side de ydre styringsbetingelser, og kravet...... kompetencemål skal de studerendes opnå selvstyret læring for at kvalificere sig til kommende profession, videreuddannelse, livslang læring og professionsudvikling. Denne kvalificering kan være i risiko for at blive undergravet af den centrale styring. På baggrund heraf undersøges problemstillingen: Hvordan...... studerendes fremtidige professionspraksis. Det anbefales, at der arbejdes både centralt og decentralt med at minimere de studerendes dilemmaposition mellem central styring og autonomi til gavn for samfundet og brugerne af de professionelles ydelser....
Mumith, A; Thomas, M; Shah, Z; Coathup, M; Blunn, G
Increasing innovation in rapid prototyping (RP) and additive manufacturing (AM), also known as 3D printing, is bringing about major changes in translational surgical research. This review describes the current position in the use of additive manufacturing in orthopaedic surgery. Cite this article: Bone Joint J 2018;100-B:455-60.
The Manufacturing Technologies Center is an integral part of Sandia National Laboratories, a multiprogram engineering and science laboratory, operated for the Department of Energy (DOE) with major facilities at Albuquerque, New Mexico, and Livermore, California. Our Center is at the core of Sandia`s Advanced Manufacturing effort which spans the entire product realization process.
Mobile energy recording unit - the basis to improve energy productivity with principles of lean production; Mobile Energie-Erfassungseinheit (MobEE). Eine Grundlage zur Steigerung der Energieproduktivitaet auf Basis von Lean Production Prinzipien
Schnellbach, Peter [Fraunhofer IWU, Augsburg (Germany). Projektgruppe fuer Ressourceneffiziente mechatronische Verarbeitungsmaschinen; Beisbart, Ulrich [BMW Group, Muenchen (Germany). Abt. Steuerung Facility Management, Energie, Mobilitaet, Dienstleistungsmanagement; Reinhardt, Gunther [Technische Univ. Muenchen (Germany). Inst. fuer Werkzeugmaschinen und Betriebswissenschaften; RMV Augsburg (Germany). IWU Projektguppe; Schneider, Oliver
Improvement of energy productivity in production processes will become more important in future. As one large customer, manufacturing industry has to take responsibility to make its contribution in this field. The mobile energy recording unit helps to create the necessary transparency to identify possible energy savings on the basis of lean production principles.
Sanders, Janet H; Karr, Tedd
Lean and Six Sigma are continuous improvement methodologies that have garnered international fame for improving manufacturing and service processes. Increasingly these methodologies are demonstrating their power to also improve healthcare processes. The purpose of this paper is to discuss a case study for the application of Lean and Six Sigma tools in the reduction of turnaround time (TAT) for Emergency Department (ED) specimens. This application of the scientific methodologies uncovered opportunities to improve the entire ED to lab system for the specimens. This case study provides details on the completion of a Lean Six Sigma project in a 1,000 bed tertiary care teaching hospital. Six Sigma's Define, Measure, Analyze, Improve, and Control methodology is very similar to good medical practice: first, relevant information is obtained and assembled; second, a careful and thorough diagnosis is completed; third, a treatment is proposed and implemented; and fourth, checks are made to determine if the treatment was effective. Lean's primary goal is to do more with less work and waste. The Lean methodology was used to identify and eliminate waste through rapid implementation of change. The initial focus of this project was the reduction of turn-around-times for ED specimens. However, the results led to better processes for both the internal and external customers of this and other processes. The project results included: a 50 percent decrease in vials used for testing, a 50 percent decrease in unused or extra specimens, a 90 percent decrease in ED specimens without orders, a 30 percent decrease in complete blood count analysis (CBCA) Median TAT, a 50 percent decrease in CBCA TAT Variation, a 10 percent decrease in Troponin TAT Variation, a 18.2 percent decrease in URPN TAT Variation, and a 2-5 minute decrease in ED registered nurses rainbow draw time. This case study demonstrated how the quantitative power of Six Sigma and the speed of Lean worked in harmony to improve
Juliana Keiko Sagawa
Full Text Available The main goal of Lean Manufacturing is the reduction of waste and consequently the improvement of manufacturing efficiency and quality. This paper presents a case study in a company from the pharmaceutical, health and food industry. The value stream was mapped, aiming to identify waste and the possible ways of reducing it, according to the lean principles. Among the proposed solutions is the implementation of Kanban cards and the implementation of a panel for stock control and production leveling (heijunka. A 70% reduction of the total lead time was estimated as a potential result (from 71 to 19 days. The proposed improvements sought to provide a balance given the trade-off between more flexible production with smaller batches, and the lower total set up time of larger batches.
Making IT Lean: Applying Lean Practices to the Work of IT presents Lean concepts and techniques for improving processes and eliminating waste in IT operations and IT Service Management, in a manner that is easy to understand. The authors provide a context for discussing several areas of application within this domain, allowing you to quickly gain insight into IT processes and Lean principles.The text reviews IT Service Management, with reference to the IT Infrastructure Library (ITIL®) as a framework for best practices-explaining how to use it to accommod
Full Text Available Lean manufacturing deals with a manufacturing process improvement based on the fundamental goal of Toyota production system in order to minimize or eliminate waste while maximizing production flow. Today in a highly competitive local and global market, it is very much crucial to satisfy the changing demand of the customers. Thus, in today’s manufacturing industry there is an increased focus to produce the right product at right time. The prime objective of this paper to apply a significant lean manufacturing tool know as Value Stream Mapping (VSM. To fulfil this objective a fundamental principles of lean were implemented and VSM was generated to analyse the production flow at an automotive industry and improve the current operating condition to overcome the difficulties with current state of work through time study, Takt time calculation, modifying work cell layout. And based on the future state of VSM, final results showed that by implementing this lean techniques, Production Lead-time (PLT decreased from 7.6 days to 3.2 days, and the cycle time is decrease up to 73%.
Lean philosophy was used to analyze the efficiency of bridge inspection. Emphasis was put on identifying activities that add value to the final output, an owner approved bridge inspection report. 26 bridge inspections were shadowed. Time spent on bri...
Simone Tavares Fernandes
Full Text Available This work presents the application of Lean Six Sigma in a case study of a metallurgic industry. The Six Sigma and the Lean are two processes used by enterprises in Brazil and worldwide. Currently the integration of these processes is a challenge for these companies, which search a way more efficient to reduce their wastes and to adapt to the needs of their markets. The paper had as purpose to demonstrate the applicability of the Lean Six Sigma in a real logistical problem related to the transportation of goods among units of a metallurgic industry. The stages used for the solution of the problem follow the DMAIC cycle – Define, Measure, Analyze, Improve and Control. The paper presents in details the integrated approach of the improvement processes Lean and Six Sigma, their tools set, as well the excellent results obtained in the case study.