Lean production as a tool for green production: the Green Foundry case study

Container terminals are the typical representatives of complex supply chain logistics hubs with multiple compound attributes and multiple coupling constraints, and their operations are provided with the strong characteristics of dynamicity, nonlinearity, coupling, and complexity (DNCC). From the perspective of computational logistics, we propose the container terminal logistics generalized computing architecture (CTL-GCA) by the migration, integration, and fusion of the abstract hierarchy, design philosophy, execution mechanism, and automatic principles of computer organization, computing architecture, and operating system. The CTL-GCA is supposed to provide the problem-oriented exploration and exploitation elementary frameworks for the abstraction, automation, and analysis of green production at container terminals. The CTL-GCA is intended to construct, evaluate, and improve the solution to planning, scheduling, and decision at container terminals, which all are nondeterministic polynomial hard problems. Subsequently, the logistics generalized computational pattern recognition and performance evaluation of a practical container terminal service case study is launched by the qualitative and quantitative approach from the sustainable perspective of green production. The case study demonstrates the application, utilization, exploitation, and exploration of CTL-GCA preliminarily, and finds the unsustainable patterns of production at the container terminal. From the above, we can draw the following conclusions. For one thing, the CTL-GCA makes a definition of the abstract and automatic running architecture of logistics generalized computation for container terminals (LGC-CT), which provides an original framework for the design and implementation of control and decision mechanism and algorithm. For another, the CTL-GCA can help us to investigate the roots of DNCC thoroughly, and then the CTL-GCA makes for conducting the efficient and sustainable running pattern recognition of LGC-CT. It is supposed to provide a favorable guidance and supplement to define, design, and implement the agile, efficient, sustainable, and robust task scheduling and resource allocation for container terminals by computational logistics whether in the strategy level or the tactical one.

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Lean Production Assessment: Case Study in Auto Parts Companies from Brazil and Spain

2011 International Conference on Management and Service Science ◽

10.1109/icmss.2011.5998231 ◽

2011 ◽

Cited By ~ 1

Author(s):

Felipe Calarge ◽

Fabio Pereira ◽

Eduardo Guilherme Satolo ◽

Luis Eugenio Carretero Diaz

Keyword(s):

Lean Production ◽

Auto Parts

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Classification and relationships between risks that affect lean production implementation

Journal of Manufacturing Technology Management ◽

10.1108/jmtm-12-2012-0113 ◽

2015 ◽

Vol 26 (1) ◽

pp. 57-79 ◽

Cited By ~ 36

Author(s):

Giuliano Almeida Marodin ◽

Tarcísio Abreu Saurin

Keyword(s):

Factor Analysis ◽

Lean Production ◽

Shop Floor ◽

Management Support ◽

The South ◽

Multiple Sources ◽

Content Type ◽

Confirmatory Factor ◽

South Of Brazil

Purpose – The purpose of this paper is twofold: to classify the risks that affect the lean production implementation (LPI) process, and to demonstrate how that classification can help to identify the relationships between the risks. Design/methodology/approach – Initially, a survey was conducted to identify the probability and impact of 14 risks in LPI, which had been identified based on a literature review. The sample comprised 57 respondents, from companies in the south of Brazil. An exploratory factor analysis was carried out to analyze the results of the survey, allowing the identification of three groups of risks in LPI. Then, a case study was conducted in one of the companies represented in the survey, in order to identify examples of relationships between the risks. Multiple sources of evidence were used in the case study, such as interviews, observations and documents analysis. Findings – The risks that affect LPI were grouped into three categories: management of the process of LPI, top and middle management support and shop floor involvement. A number of examples of relationships between the risks were identified. Research limitations/implications – The survey was limited to companies from the south of Brazil and therefore its results cannot be completelly generalized to other companies. Moreover, the results of the survey were not subjected to a confirmatory factor analysis. Originality/value – This study helps to improve the understanding of LPI, as: it re-interprets the factors, barriers and difficulties for LPI from the perspective of risk management, which had not been used for that purpose so far; it presents a classification of the risks that affect LPI, which can support the understanding of the relationships between the risks and, as a result, it can support the development of more effective methods for LPI.

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Lean production in manual assembly line — A case study

2012 IEEE Symposium on Humanities, Science and Engineering Research ◽

10.1109/shuser.2012.6268997 ◽

2012 ◽

Author(s):

Low Shye Nee ◽

Goh Wen Juin ◽

Fow Jun Yan ◽

Chan Yee Theng ◽

S. Kamaruddin

Keyword(s):

Assembly Line ◽

Lean Production ◽

Manual Assembly

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Implementing a lean production system on a food company: a case study

International Journal of Engineering Management and Economics ◽

10.1504/ijeme.2015.069904 ◽

2015 ◽

Vol 5 (1/2) ◽

pp. 129 ◽

Cited By ~ 1

Author(s):

Mª Victoria De La Fuente Aragón ◽

Lorenzo Ros McDonnell

Keyword(s):

Production System ◽

Lean Production ◽

Food Company

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Developing a lean production organization: an Australian case study

International Journal of Operations & Production Management ◽

10.1108/01443579610109866 ◽

1996 ◽

Vol 16 (2) ◽

pp. 91-102 ◽

Cited By ~ 35

Author(s):

Amrik S. Sohal

Keyword(s):

Lean Production ◽

Australian Case ◽

Production Organization

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Implementation of hybrid Kanban-CONWIP system: a case study

Journal of Manufacturing Technology Management ◽

10.1108/jmtm-03-2016-0043 ◽

2017 ◽

Vol 28 (6) ◽

pp. 714-736 ◽

Cited By ~ 11

Author(s):

Dênis Gustavo Leonardo ◽

Bruno Sereno ◽

Daniel Sant Anna da Silva ◽

Mauro Sampaio ◽

Alexandre Augusto Massote ◽

...

Keyword(s):

Control Systems ◽

Hybrid System ◽

Production Control ◽

Job Shop ◽

Lean Production ◽

Shop Floor ◽

Content Type ◽

Floor Control ◽

Low Volume

Purpose Shop floor control systems are generally major points of discussion in production planning and control literature. The purpose of this paper is to investigate how lean production control principles can be used in a make-to-order (MTO) job shop, where the volume is typically low and there is high variety. This paper examines the procedures involved in implementing a constant work-in-process (CONWIP)/Kanban hybrid system in the shop floor environment and also provides insights and guidelines on the implementation of a hybrid system in a high-variety/low-volume environment. Design/methodology/approach The authors review literature on Kanban, CONWIP, and CONWIP/Kanban hybrid systems to analyze how lean production control principles can be used in a MTO job shop. The second part focuses on the process of implementation. Using a case study of a manufacturer of electromechanical components for valve monitoring and controls, the paper describes how the operation is transformed by for more efficient shop floor control systems. Real experiments are used to compare pre- and post-improvement performance. Findings The study shows that the proposed hybrid Kanban-CONWIP system reduced the cycle time and achieved an increase of 38 percent in inventory turnover. The empirical results from this pilot study provide useful managerial insights for a benchmarking analysis of the actions to be taken into consideration by companies that have similar manufacturing systems. Research limitations/implications The statistic generalization of the results is impossible due to the use of a single case method of study. Originality/value This paper provides insights and guidelines on the implementation of a hybrid system in a high-variety/low-volume environment. The literature on real applications of hybrid CONWIP/Kanban by case study is limited.

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Definition of a Protocol for Implementing Lean Production Methodology in Textile and Clothing Case Studies

Volume 2B: Advanced Manufacturing ◽

10.1115/imece2013-64739 ◽

2013 ◽

Author(s):

Laura Costa Maia ◽

Anabela Carvalho Alves ◽

Celina P. Leão

Keyword(s):

Work Environment ◽

Case Studies ◽

Lean Production ◽

Doctoral Program ◽

Industrial Engineering ◽

Clothing Industry ◽

Preliminary Results ◽

Definition Of ◽

National Framework

This paper presents a protocol used in case studies with the objective to validate a Lean Production methodology in Textile and Clothing Industry (TCI) in North of Portugal. The methodology was developed under a Doctoral Program on Industrial Engineering and Systems. During the development of the methodology, the TCI contextualization was studied in parallel with the development of a survey applied to the TCI companies. The development of the methodology (structured in three phases) was followed by its validation in case studies. Thus, this paper objective is to describe and explain the case study designed and conducted to attain feedback from companies. These case studies demanded a protocol constituted by an overview of the project, the field procedures (meetings and visits, interviews, questionnaires and checklist form), the preliminary questions of the project and the guide for the reports from the case studies. From the field procedures, the interviews was the first instrument used and it allowed the identification of the needs of change, the workers and management role in this change, the expected and achieved results. These preliminary results are presented in this paper. The questionnaire, adapted from others studies, would be used for a better context in the national framework and it would be applied in a following phase as the checklist. It will enable the data and metrics collection related with several aspects, namely work ergonomic conditions. This protocol will allow the knowledge of the work environment for a good implementation of the Lean Production.

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