scholarly journals Introduction to Lean Waste and Lean Tools

2021 ◽  
Author(s):  
Shyam Sunder Sharma ◽  
Rahul Khatri

In the turbulent and complex business environments, many Indian SMEs are facing stiff competition in the domestic as well as in the global market from their multinational counterpart. The concept of lean has gained prominence due to the fact that the resource based competitive advantages are no longer sufficient in this economy. Hence, lean is no longer merely an option but rather a core necessity for engineering industries situated in any part of the globe, if they have to compete successfully. Lean Manufacturing (LM) which provides new opportunities to create and retain greater value from the employee of the industry based on their core business competencies. The challenge of capturing, organizing, and disseminating throughout the aggregate business unit is a huge responsibility of the top management. The success of any industry depends on how well it can manage its resources and translate in to action. The adoption of lean manufacturing through effective lean practices depends on interpretations of past experiences and present information resides in the industry. Generally, in an industry, some tangible and intangible factors exist in the form of non-value adding activities which hinder the smooth lean implementation are known as lean manufacturing barriers (LMBs).

2016 ◽  
Vol 7 (2) ◽  
pp. 136-148 ◽  
Author(s):  
Seyed Mojib Zahraee

Purpose Lean manufacturing (LM) practices and tools are among the key concepts that assist managers and engineers sustain competitiveness in an expanding global market. The purpose of this paper is to identify effective practices and tools of lean manufacturing implementation in an Iranian manufacturing industry. Design/methodology/approach This study used a quantitative method. Stratified random sampling and self-administrated questionnaires were sent to respondents in an Iranian manufacturing industry. Findings The final results indicate that processes and equipment, planning and control, supplier relationship, human resources and customer relations are significant practices in lean manufacturing in Iranian manufacturing factories. The results from this survey additionally show that lean tools such as Kaizen, 5S, setup time reduction, cellular manufacturing, continuous flow, equipment layout, product design simplicity and error proof equipment are crucial to lean manufacturing implementation. Research limitations/implications This study focused solely on a manufacturing industry in Iran that deals with electrical, electronic, metal, plastic, rubber and other automotive components. Practical implications The findings of this study emphasize some implications and suggest that reducing cost is more effective and decreased inventory is less effective on lean manufacturing implementation. The current study results should assist quality mangers, product managers and director managers as well as academicians. Originality/value An investigation was carried out in this study based on the current situation of Iran’s manufacturing industry to empirically examine and evaluate the effect of lean practices and tools. Besides, a very limited number of studies have been done regarding the implementation of lean thinking and practices in Iran’s manufacturing industry.


2002 ◽  
Vol 21 (3) ◽  
pp. 169-181
Author(s):  
Mercedes Úbeda García ◽  
Francisco Llopis Vañó

We could characterize today's business world with numerous attributes, namely: dynamism, turbulence, complexity, etc. But if we had to give a brief definition of the specific challenges business management will have to face in the next century, the best choice would surely be talking about ‘global market’ and ‘knowledge management’. These are the two concepts we have tried to combine in this paper, trying to emphasize the starring role human resources management must play in this scenario. The globalization of economy is already a reality firms currently have to face, but what is the role of knowledge, or of those who own that knowledge (human resources) within a global framework? If we analyze the human capital in an firm according to the resource-based view of the firm, we can consider knowledge as an intangible resource on which organizations can build up their competitive advantages and keep them with the pass of time; and knowledge management can be seen as a strategic capability as long as the practices being used encourage the development and accumulation of a knowledge stock that will allow the firm to design an operating procedure which no other competitors can imitate. It will have to be the human resources management's task to generate a leverage among individual competences through the construction of an Organizational Learning Scheme. Organizational Learning can be understood as a collective phenomenon in which new knowledge is acquired by the members of an organization with the aim of settling, as well as developing, the core competences in the firm, taking individual learning as the basic starting point. There are various ways an firm can follow when it comes to learning, two of which stand out from the others: through accumulated experience or through experimentation, both of which are compatible with the concept of globalization, or with the decision made by an firm to start working overseas, that is, to become internationalized. An firm can choose to operate in a global market in order to achieve a higher income through the exploitation of its know-how, its brand name, or the management capabilities of the domestic firm in different countries. Thus, if we consider human knowledge as a key strategic factor on which competitive advantages can be built, we could justify the value of human resources in firms which start operating on an international scale through the competences that these human resources can develop, among which we can highlight the role played by the competences of the human capital from the parent company. In this case, the organization would be resorting to learning through accumulated experience. But we cannot forget that if the firm exploits exclusively its core competences, without trying to accumulate new distinctive competences, it will suffer, in the long run, a competitive disadvantage, insofar as it will have to face the competition of firms highly motivated by the learning that their resource basis will have developed, which will alter the competition terms. In this sense, we could consider the firm's internationalization as being, apart from a procedure to strengthen and exploit the firm's strategic competences, as a way of revitalizing or renewing them, reconfigurating the ‘domestic knowledge’ by means of other knowledge, through addition and combination, a new knowledge arising this way. On the other hand, it is in turn not an easy task to exploit and to achieve a return on domestic knowledge (which normally has an implicit nature) in other countries, and it is even more difficult to follow a conversion cycle so that new knowledge can be incorporated. Thus, we can highlight, as possible ways of transferring basic knowledge, imitation through the practical exercise of the head firm's operating procedures (using an ethnocentric approach), carrying out an exchange of experiences and, above all, two of the most commonly used actions in firms having to face internationalization processes, namely, the transfer of employees and the use of expatriates. The way in which that knowledge is later complemented and combined with that of the other entities, will depend on the learning rate reached in each specific unit, although we must point out that one of the critical factors when it comes to the achievement of an Organizational Learning Scheme is the consolidation of a cultural framework which encourages permanent improvement and which is specially characterized by the open attitude towards experimentation, the stimulus to take chances and the will to face failures or mistakes and to try and learn from them. In short, the study of Organizational Learning in a global market is one of the fields to be developed in human resources management, for two main reasons; on the one hand, the globalization of economy is a phenomenon which has an influence on the firms' success and, on the other hand, because competitive advantage currently lies in knowledge, and this can only have one replacement, more knowledge.


2013 ◽  
Vol 116 (1) ◽  
pp. 125-141 ◽  
Author(s):  
Manoj Dora ◽  
Dirk Van Goubergen ◽  
Maneesh Kumar ◽  
Adrienn Molnar ◽  
Xavier Gellynck

Purpose – Recent literature emphasizes the application of lean manufacturing practices to food processing industries in order to improve operational efficiency and productivity. Only a very limited number of studies have focused on the implementation of lean manufacturing practices within small and medium-sized enterprises (SMEs) operating in the food sector. The majority of these studies used the case study method and concentrated on individual lean manufacturing techniques geared towards resolving efficiency issues. This paper aims to analyze the status of the lean manufacturing practices and their benefits and barriers among European food processing SMEs. Design/methodology/approach – A structured questionnaire was developed to collect data. A total of 35 SMEs' representatives, mostly CEOs and operations managers, participated in the survey. The study investigated the role of two control variables in lean implementation: size of the company and country of origin. Findings – The findings show that lean manufacturing practice deployment in food processing SMEs is generally low and still evolving. However, some lean manufacturing practices are more prevalent than others; e.g. flow, pull and statistical process control are not widely used by the food processing SMEs, whereas total productive maintenance, employee involvement, and customer association are more widespread. The key barriers encountered by food SMEs in the implementation of lean manufacturing practices result from the special characteristics of the food sector, such as highly perishable products, complicated processing, extremely variable raw materials, recipes and unpredictable demand. In addition, lack of knowledge and resources makes it difficult for food processing SMEs to embark on the lean journey. Originality/value – The gap in the literature regarding the application of lean manufacturing in the food sector is identified and addressed in this study. The originality of this paper lies in analyzing the current status of the use of lean manufacturing practices among food SMEs in Europe and identifying potential barriers.


2015 ◽  
Vol 35 (3) ◽  
pp. 370-391 ◽  
Author(s):  
Frank Wiengarten ◽  
Cristina Gimenez ◽  
Brian Fynes ◽  
Kasra Ferdows

Purpose – The purpose of this paper is to assess the influence of cultural collectivism on the efficacy of lean practices. Furthermore, this study assesses whether or not potential cultural disadvantages related to the level of individualism at the national level can be compensated for at the organisational culture level. Design/methodology/approach – Hofstede’s cultural dimension of individualism is used to test whether practicing a collectivistic culture at the organisational level can fully compensate for the potential disadvantages of being geographically situated in an individualistic culture when practicing lean manufacturing. Findings – Results suggest that cultural collectivism at the national and organisational level have a significant impact on the efficacy of lean practices. Furthermore, the negative impact of being situated in an individualistic country cannot be fully compensated for through practicing a collectivistic organisational culture when practicing lean. Originality/value – This study represents a comprehensive attempt to simultaneously assess the collectivism cultural components of lean practices at the national as well as at the organisational level.


2014 ◽  
Vol 592-594 ◽  
pp. 2628-2638 ◽  
Author(s):  
T.G. Arul ◽  
C. Arumugam ◽  
P. Parthiban

Lean manufacturing is a management philosophy derived from Toyota Production System (TPS) which aims to increase the overall values of the product or service provided to the customer through elimination of non-value added activities. In the era of globalisation, to remain competitive in the global market, many medium and small sized Indian industries adopt lean manufacturing. This paper focuses on implementation of lean manufacturing in Indian MSMEs. To examine the implementation, attributes which influence lean manufacturing are obtained and industries’ performances on these criteria are rated. In this paper, the methodology selected from many of the multi criteria models is the Technique for Order Preference by Similarity to Ideal Solution (TOPSIS). In the actual real world situation, because of the unreliable nature of the information gathered, the attributes are often not absolute and are imprecise. These data can be considered as fuzzy and the aim of this paper is to adopt TOPSIS decision making method to problems with fuzzy data. The rating and weights of each data are expressed as triangular fuzzy numbers. These attributes are then normalized and the TOPSIS methodology is carried out to determine the effect of implementing lean manufacturing technique in an industry. The best industry is identified by fuzzy TOPSIS on the basis of performance towards the considered attributes is consistent with results identified by TOPSIS.


Author(s):  
Н.С. Хорошавина ◽  
М.С. Абрашкин

Цифровые технологии существенно влияют на мировой рынок, внося коррективы в расстановку сил на нем. Используемые ранее подходы к управлению бизнес-процессами становятся не актуальными в современных условиях. Без цифровизации наукоемкие производства будут не способны выдержать конкурентную борьбу, и вынуждены будут уйти с рынка. В то же время современные условия хозяйствования диктуют необходимость постоянного совершенствования бизнес-процессов наукоемких предприятий, их оптимизации. Данные принципы являются основой концепции бережливое производство, реализация которых становится более эффективной при условии использования цифровых технологий. В статье рассмотрены вопросы интеграции концепции бережливое производство и цифровых технологий на наукоемких предприятиях. Показан пример успешной реализации принципов данной концепции с использованием цифровых подходов к оптимизации бизнес-процессов наукоемкого производства. В современных условиях важнейшим активом любого предприятия, в том числе и наукоемкого производства, являются данные. Реализация принципов бережливого производства требует обработки значительного объема информации. Цифровые технологии позволяют анализировать информационные потоки в режиме реального времени, моделировать бизнес-процессы и тем самым, способствуют более качественному и оперативному принятию решений по оптимизации бизнес-процессов наукоемких производств. Только объединив принципы концепции бережливое производство и возможности, которые дает цифровизация, наукоемкие предприятия смогут не просто удержать свои конкурентные позиции на рынке, но и перейти на более качественный уровень своего развития. Digital technologies significantly affect the global market, making adjustments to the balance of power in it. Previously used approaches to business process management are no longer relevant in modern conditions. Without digitalization, high-tech industries will not be able to withstand competition and will be forced to leave the market. At the same time, modern business conditions dictate the need to constantly improve the business processes of high-tech enterprises and optimize them. These principles are the basis of the concept of lean manufacturing, the implementation of which becomes more effective when using digital technologies. The article deals with the integration of the concept of lean manufacturing and digital technologies in high-tech enterprises. An example of successful implementation of the principles of this concept using digital approaches to optimizing business processes in high-tech production is shown. In modern conditions, the most important asset of any.


2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Hemant Sharma ◽  
Nagendra Sohani ◽  
Ashish Yadav

PurposeIn the recent scenario, there has been an increasing trend toward lean practices and implementation in production systems for the improvement of an organization’s performance as its basic nature is to eliminate the wastes. The increasing interest of customers in customized products and the fulfillment of customers’ demand with good productivity and efficiency within time are the challenges for the manufacturing organization; that is why adopting lean manufacturing concept is very crucial in the current scenario.Design/methodology/approachIn this paper, the authors considered three different methodologies for fulfilling the objective of our research. The analytical hierarchy process, best–worst method and fuzzy step-wise weight assessment ratio analysis are the three methods employed for weighting all the enablers and finding the priority among them and their final rankings.FindingsFurther, the best results among these methodologies could be used to analyze their interrelationships for successful lean supply chain management implementation in an organization. In this paper, 35 key enablers were identified after the rigorous analysis of literature review and the opinion of a group of experts consisting of academicians, practitioners and consultants. Thereafter, the brainstorming sessions were conducted to finalize 28 lean supply chain enablers (LSCEs).Practical implicationsFor lean manufacturing practitioners, the result of this study can be beneficial where the manufacturer is required to increase efficiency and reduce cost and wastage of resources in the lean manufacturing process.Originality/valueThis paper is the first of the research papers that considered deep literature review of identified LSCEs as the initial step, followed by finding the best priority weightage and developing the ranking of various lean enablers of supply chain with the help of various methodologies.


2011 ◽  
pp. 279-291
Author(s):  
S.R. Balasundaram ◽  
B. Ramadoss

The rapidly changing nature of business environments requires organizations to be more flexible to gain competitive advantages. Organizations are turning into a new generation of software called Enterprise Application Integration (EAI) to fully integrate business processes. It is an activity that integrates and harmonizes an enterprise’s isolated business applications, processes and functions involving real time data. Developing quality EAI projects is quite a big challenge. Even though success of EAI projects depends on so many parameters, ‘testing’ is the most significant phase that can ensure the quality as well as the success of EAI projects. Components integrated without testing in EAI systems may affect the enterprise system as a whole. This chapter focuses on the testing aspects related to EAI applications. Especially the significance of testing for various types of “Integrations” is discussed in detail.


Author(s):  
Drago Dubrovski

In modern business, dynamic changes in the environment (macro trends) provoke changes within the company. Companies can protect themselves from latent, acute crises. In addition, companies can navigate a turbulent environment while ensuring organizational existence and development. Organizational forms and characteristics, as well as business models to maintain or increase existence and create competitive advantages in the global market, are increasingly sought in a more creative manner. These actions are based on dynamic strategic thinking. Revolutionary methods are often required for the creation and adaptation of competitive business models. The data from companies that face a current crisis show a gap between the need to change business models and the introduction of adapted business models to achieve the desired level of competitiveness.


Author(s):  
Bikem Türkeli ◽  
Alp Ariburnu ◽  
Özalp Vayvay

In a time of rapid revolutionary change, today organizations must innovate in ways that allow them to take advantage of change. Competitive business environments force companies to respond to all changes in the market. This response to that change brings innovation in processes. As a basis of all competitive advantages, innovation should be continuous and the only way to maintain this is having the right innovation strategy. In this study innovative strategies for logistics processes, which can be used practically in business environments, are mentioned. For each innovative strategy title tools that can be used to innovate operations are presented. By innovating logistics processes logistics providers can fulfill customer needs rapidly and increase their profit because of having a competitive advantage.


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