Application of lean manufacturing tools and techniques for waste reduction in Nigerian bricks production process

2019 ◽  
Vol 27 (3) ◽  
pp. 658-679
Author(s):  
Adefemi Aka ◽  
Abubakar Danladi Isah ◽  
Chukwudum J. Eze ◽  
Owolabi Timileyin
Keyword(s):  
Production Process ◽  
Construction Industry ◽  
Lean Manufacturing ◽  
Mixed Methods Research ◽  
Phenomenological Study ◽  
Waste Reduction ◽  
Lean Thinking ◽  
Content Type ◽  
Study Context ◽  
Tools And Techniques

Purpose Non-value adding activities or wastes in the lean term have been the major challenge of the construction industry. Numerous studies have been conducted to investigate how such wastes can be reduced so as to improve the performance of the construction industry. However, the aspect of bricks production process (BPP) has not been extensively covered. Therefore, the purpose of this paper is to investigate the application of lean manufacturing concepts in BPP with a view to identifying the various wastes in the practice, the causes of these wastes and how such wastes can be reduced. Design/methodology/approach Mixed methods research design was adopted by the researchers where literature review was first conducted to establish the fundamental theories and practice standards of lean manufacturing process. Thereafter, a phenomenological study was carried out in a Shelter Clay and Brick Factory located in Minna, Niger State, Nigeria. The data obtained in the phenomenological study were analyzed through content analysis. These data served as the basis for the validation survey that subsequently followed the phenomenological study. Findings The findings in the study show that poor or inadequate supervision is the main factor responsible for wastes such as excessive drying of bricks, overheating of bricks and re-glazing of bricks in Nigerian BPP. Research limitations/implications The study focused on the various wastes in Nigerian BPP. It also focused on the various lean tools/techniques that can be adopted to reduce the wastes. Aspects such as the percentage of the wastes and their cost implication on the factory were not covered during the study and could be further investigated by prospective researchers. Practical implications The study provides knowledge on how lean thinking can be adopted to reduce wastes in BPP. Such knowledge may be beneficial to the present and prospective bricks producers. This implies that the proposed framework in the study allows producers of bricks to identify gaps in their implementation efforts, focus attention on areas that may require improvements, and access the benefits of lean approach in their factory products. The proposed framework may also be beneficial to the academics. Originality/value This paper first gain originality in the study context to propose for a lean framework that can be adopted to reduce wastes in BPP. Furthermore, the paper has not been previously published and all the information obtained from other sources are duly referenced.

A conceptual framework for waste identification and reduction in Nigerian sandcrete blocks production process

2019 ◽  
Vol 19 (3) ◽  
pp. 405-423 ◽  
Author(s):  
Adefemi Aka ◽  
Abosede Adebisi Bamgbade ◽  
Ibrahim Saidu ◽  
Oladimeji Moses Balogun
Keyword(s):  
Production Process ◽  
Building Blocks ◽  
Value Stream Mapping ◽  
Long Distance ◽  
Content Type ◽  
Value Stream ◽  
Process Waste ◽  
Future State ◽  
Study Context ◽  
Tools And Techniques

Purpose Non-value adding activities or waste have been a major challenge for the construction industry. Researchers worldwide have investigated how such activities can be reduced or overcome in the industry. However, much has not been done regarding waste in the production process of building blocks. Therefore, this study aims to investigate the various waste in sandcrete blocks production process (SBPP). The study also aims to find out the causes of the waste and their impacts on the factory performance. Design/methodology/approach To achieve the aims of this study, a qualitative study was conducted in five sandcrete blocks firms in Minna. Physical observation and interviews were the main instruments used for data collection. The data obtained were analyzed through content analysis. Samples of blocks (low standard only) were also taken to the laboratory for compressive and porosity tests. Thereafter, questionnaires were administered to other sandcrete blocks producers in six firms. The essence of this was to investigate the applicability of the identified waste in other factories in the study context and for further data analysis. Findings Typical forms of waste in SBPP are excessive stocking of sand and cement, long distance covered from the store to the mixing or production location, excessive quantity or over design of materials and over vibration or compaction of the newly produced blocks. It is anticipated that adoption of lean concepts, tools and techniques in the production of sandcrete blocks will help to eradicate the identified waste in the process and stimulate a future state value stream mapping (VSM). The practicality of the expected future state VSM is presently being investigated by one of the five firms in the study context. Research limitations/implications The findings of the study mainly provide further insights on the various process waste in Nigerian sandcrete blocks production. Practical implications The study provides knowledge on how lean thinking can be adopted to identify and reduce waste in SBPP. Such knowledge may be beneficial to the present and prospective sandcrete blocks producers. The study also provides insight on how the overall cost of production of sandcrete blocks and the quantity of CO2 that is being released into the atmosphere in the production process can be reduced. The VSM in the proposed framework also serves as a tool that can be globally adopted for waste identification by producers of other forms of blocks such as bricks. Originality/value This paper satisfies all the tenets of originality as it has not been previously published and all the information obtained from other studies have been duly referenced. The study is also original as it is first in the study context to propose for a lean framework that can be used to reduce waste in SBPP.

scholarly journals From Lean Manufacturing to Lean Construction: How Principles, Tools, and Techniques Evolved

2021 ◽  
Author(s):  
Sevilay Demirkesen
Keyword(s):  
Construction Industry ◽  
Automotive Industry ◽  
Lean Manufacturing ◽  
Traditional Approach ◽  
Lean Construction ◽  
Work Practices ◽  
Lean Tools ◽  
Low Efficiency ◽  
Tools And Techniques ◽  
Lean Methods

Lean manufacturing first emerged in the automotive industry. However, low productivity and low efficiency in production are major problems for the majority of industries relying on a heavy workforce. Being one of these, the construction industry suffers from low productivity rates along with inefficient work practices. To prevent those, the industry has shifted its focus from the traditional approach to a more innovative one, which is called Lean construction. Lean construction aims to maximize value while minimizing waste. Therefore, it intends to create safer, smoother, and more efficient processes to eliminate waste. This chapter focuses on Lean construction and highlights the generic Lean tools and techniques practiced in the construction industry indicating its historical journey from Lean manufacturing. The chapter aims to raise awareness towards the efficiency of Lean methods in the construction industry with respect to practices observed in manufacturing.

Managing industrial operations by lean thinking using value stream mapping and six sigma in manufacturing unit

2019 ◽  
Vol 58 (6) ◽  
pp. 1118-1148 ◽  
Author(s):  
Jagdeep Singh ◽  
Harwinder Singh ◽  
Amandeep Singh ◽  
Jashanpreet Singh
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lead Time ◽  
Manufacturing Industry ◽  
Value Stream Mapping ◽  
Lean Thinking ◽  
Content Type ◽  
Value Stream ◽  
Future State ◽  
Industrial Operations

Purpose The purpose of this paper is to cover the significance of lean thinking using value stream mapping and six sigma methodology in managing industrial operations. Design/methodology/approach Lean manufacturing is an efficient approach for identifying and eliminating waste through a continuous improvement via flow of the product/service at the pull of customer in chase of exactness. This study has been carried out in a manufacturing unit of Northern India that was suffering from high production lead time and work in progress (WIP) inventory. Findings The current state and future state maps for the critical product have been prepared. On comparison of both current and future state maps, it was observed that lead time has been reduced by 14.88 percent, processing time by 14.71 percent and wastage of material movement by 37.97 percent. As proposed in model, the WIP inventories have been reduced by 17.76 percent and workforce by 17.64 percent. Further it would lead to the profit of Rs161,800 per annum. Six sigma projects have been carried out to reduce rejections of the critical product P-19 under study. The total length of the product was undersize of the critical product. Root cause analysis technique has been used through strategic DMAIC implementation. Results of investigation demonstrated net savings of rupees 145,560 annually. Originality/value The paper demonstrates the practical application of lean thinking, showing how it can bring real breakthroughs in saving cost in the manufacturing industry.

scholarly journals 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)

2015 ◽  
Vol 35 (02) ◽  
pp. 205
Author(s):  
Aditya Nugroho ◽  
Makhmudun Ainuri ◽  
Nafis Khuriyari
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Raw Materials ◽  
Waste Reduction ◽  
Value Stream

“Mi Lethek” industry is an industry that produce dry noodles. In the production process of “Mi Lethek” industry, unnecessary inventory and excessive transportation. To reduce that waste, lean manufacturing approach is required. industry was 12,05%. The recommendations for increase PCE are relayouting the plant and change the order schedulingof 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”

scholarly journals BARRIERS TO IMPLEMENTATION OF LEAN CONSTRUCTION TECHNIQUES IN GUJARAT CONSTRUCTION INDUSTRY

2021 ◽  
Vol 8 (4) ◽  
pp. 17-24
Author(s):  
Harshil Thakkar ◽  
Vismay A. Shah
Keyword(s):  
Construction Industry ◽  
Lean Manufacturing ◽  
Resistance To Change ◽  
Lean Construction ◽  
Project Delivery ◽  
Dominant Factor ◽  
Construction Technique ◽  
Lean Thinking ◽  
Lean Principles ◽  
Pertinent Data

Lean construction technique has been arisen from endeavouring and applying Japanese lean manufacturing philosophy to the construction industry. Large research is being done recently and an ongoing process to adopt lean principles to the construction industry to enhance the efficacy, amelioration of waste. The success of the lean technique is evident, but some major reports indicated that major challenges are related to the Mis-conceptualisation of lean thinking, and some case studies have ascertained that the lean technique was either applied partially or erroneously. The purpose of this paper is to elucidate the lean concept, wastes in construction, features of lean project delivery, lean principles and the barriers to implementing the lean technique in the Gujarat construction industry. A compendious review of the literature had been done with the perspective of reaping pertinent data needed for the paper and to make a questionnaire. To check the reliability of data Cronbach’s alpha was used. Followed by a statistical analysis of data by Relative Important Index (RII) and ranks were given. Further analysis discovered that only nine of these barriers were determined significant, where dominant factor was Resistance to change and culture with an RII value of 0.63. The results of this study could be used to help researchers, practitioners and companies in the Gujarat construction industry to fasten their attention on the suggestive issues to the prosperous implementation of the lean concept. Lean construction technique has been arisen from endeavouring and applying Japanese lean manufacturing philosophy to the construction industry. Large research is being done recently and an ongoing process to adopt lean principles to the construction industry to enhance the efficacy, amelioration of waste. The success of the lean technique is evident, but some major reports indicated that major challenges are related to the Mis-conceptualisation of lean thinking, and some case studies have ascertained that the lean technique was either applied partially or erroneously. The purpose of this paper is to elucidate the lean concept, wastes in construction, features of lean project delivery, lean principles and the barriers to implementing the lean technique in the Gujarat construction industry. A compendious review of the literature had been done with the perspective of reaping pertinent data needed for the paper and to make a questionnaire. To check the reliability of data Cronbach’s alpha was used. Followed by a statistical analysis of data by Relative Important Index (RII) and ranks were given. Further analysis discovered that only nine of these barriers were determined significant, where dominant factor was Resistance to change and culture with an RII value of 0.63. The results of this study could be used to help researchers, practitioners and companies in the Gujarat construction industry to fasten their attention on the suggestive issues to the prosperous implementation of the lean concept.

Lean and US manufacturing industry: popularity of practices and implementation barriers

2016 ◽  
Vol 65 (7) ◽  
pp. 875-897 ◽  
Author(s):  
Amir Abolhassani ◽  
Ky Layfield ◽  
Bhaskaran Gopalakrishnan
Keyword(s):  
West Virginia ◽  
Lean Manufacturing ◽  
Waste Reduction ◽  
Process Equipment ◽  
Manufacturing Companies ◽  
Improvement Program ◽  
Content Type ◽  
Lean Practices ◽  
Manufacturing Facilities ◽  
Lean Methods

Purpose The purpose of this paper is to analyze lean strategic practices being implemented in manufacturing facilities throughout Pennsylvania and West Virginia and identify the difficulty in implementing those lean practices. Design/methodology/approach A skip logic questionnaire was developed into multiple sections for analysis; demographics of respondents, identification of the knowledge and practice of lean methods, interpretation of lean application, strategic direction of lean methods, measurements of expertise, and difficulties for practicing lean. The questionnaire was sent to 327 manufacturing facilities where 51 usable responses were collected for the study. Findings Lean manufacturing is a widely recognized and practiced business philosophy as a significant percentage of manufacturers have implemented some variation of practice. However, the extent of knowledge does not mirror awareness. The application of lean manufacturing practices is not readily appropriate for every company, but adopting the concept of customer-focussed waste reduction to maximize value can be universally applied as waste reduction was the most prominent practice pursued. Lean practitioners found that poka-yoke and installing new process equipment have the highest degree of benefits from implementation while 5S and eliminating waste were the least difficult practices to implement. In general, the management personnel of the companies have an influential effect on lean manufacturing pursuance. This is illustrated by the fact of high agreement between facilities that resistance to change from employees is the most prominent difficulty for implementation followed by limited technical knowledge of lean manufacturing at operational and conceptual levels. Research limitations/implications The research findings are from a subset of manufacturing companies in Pennsylvania and West Virginia and may not represent all of the companies on a national level. The results must be interpreted in the context of the data acquisition approach due to the extent of the sample size involved, the procedure for how data were collected, and assuming that each lean strategic practice has the same weight to calculate the facility lean index. Practical implications The results provide insight about the effect of facility size and years of lean practicing for various lean strategic practices. The most beneficial and least difficult lean strategies, their implementation level, and the real challenges for implementing lean were also identified to help both lean practitioner and non-practitioner for the lean journey. Originality/value The research investigates current lean strategic practices pursued by manufacturers throughout Pennsylvania and West Virginia and identifies obstacles to implementation of lean practices. Lean manufacturing is widely sought after as a continuous improvement program, but success is divided. This study characterizes lean manufacturing comprehension while identifying knowledge areas of strengths and deficiencies. There lacks an established structure for lean practices to pursue. Therefore, this study provides manufacturers a measure for comparing their position for refined decision making.

Lean initiative practice for supplier developments in Philippines

2015 ◽  
Vol 6 (4) ◽  
pp. 349-368 ◽  
Author(s):  
Song-Kyoo Kim
Keyword(s):  
Lean Manufacturing ◽  
Supplier Development ◽  
Lean Thinking ◽  
Implementation Framework ◽  
Lean Implementation ◽  
Content Type ◽  
Automotive Parts ◽  
Lean Tools ◽  
Setup Phase

Purpose – The purpose of the paper is to demonstrate how Toyota deploys Lean Manufacturing and Toyota Production System (TPS) for their automotive parts’ suppliers in Philippines based on the case study and the literature review. Design/methodology/approach – The methods to better understand how Toyota donates Lean Manufacturing to develop their suppliers include to review the general Lean thinking process and tools and study in depth the selected Lean manufacturing tools that are directly related with Toyota supplier development and to show the actual implementations base in the case of the supplier of Toyota in Philippines. Findings – The result of the case study shows how Toyota donates their Lean manufacturing (TPS) methods to the suppliers. There are several procedures and various tools for the Lean process. But one procedure within the process and only some of the Lean tools are suitable for supplier development. The case shows that all improvements (Kaizen) during the Lean implementation should be directly intertwined onsite (Genba) and just a small amount of the Lean tools is needed in real-world situations. In other words, the consultation of the Lean implementation might not require the full package of the Lean implementations. More importantly, the consultations of the Lean implementation without deeply understanding the onsite are useless. Research limitations/implications – The project for the Lean deployment for supplier implementation is targeted to understand the full procedure from the start to the end, but the case in this paper is only covering the setup phase. As the suppliers of Toyota, there are additional parts to be implemented (i.e. shipping management), but it is not covered in this paper. Originality/value – There are some researches about Lean implementation framework, and only few cases deal with the actual Lean implementations. But the case about the Lean implementation of supplier development initiation which aligned with the Toyota Company is unique.

Applying lean thinking in an educational institute – an action research

2017 ◽  
Vol 66 (5) ◽  
pp. 598-629 ◽  
Author(s):  
Gopalakrishnan Narayanamurthy ◽  
Anand Gurumurthy ◽  
Raju Chockalingam
Keyword(s):  
Action Research ◽  
Relevant Literature ◽  
Lean Thinking ◽  
Content Type ◽  
Long Run ◽  
Educational Institute ◽  
Elective Course ◽  
Service Sectors ◽  
Tools And Techniques ◽  
The Impact

Purpose Lean thinking (LT) has been implemented in various manufacturing and service sectors. But, only a few published research articles have developed a framework describing the procedure for implementing LT in an educational institute. The purpose of this paper is to develop and demonstrate a framework that can provide a structured procedure for the implementation of LT in an educational institute. Design/methodology/approach Various LT tools and techniques applicable in educational institute were identified by reviewing the relevant literature. By adopting an action research methodology (ARM) for a time period of 28 months, the processes in a case institute were studied; wastes in the process were identified and various solutions were proposed and implemented. Findings A comparison of the performance measures before (Batch 1) and after (Batch 2) implementation of solutions provided interesting insights into the effectiveness of LT. In both the batches, absenteeism in the class was found to increase across the terms. But the magnitude of increase was lesser in Batch 2. Results also showed that the number of unfilled seats (poor utilization) in an elective course in the second year of the program drastically reduced in Batch 2. Finally, a framework that can guide LT implementation in educational institutes was proposed. Research limitations/implications The current study describes only the initial stages of implementation in an educational institute. Hence, some of the benefits discussed are expected in the long run which can be assessed by carrying out a longitudinal study. Future study can attempt to empirically validate the proposed framework in multiple educational institutes and theoretically explain the reasons behind the results obtained. Practical implications ARM can be used as a tool by practitioners to study the behavioral aspects of employees of educational institutes toward LT implementation. The proposed framework and its demonstration can assist employees in educational institutes to implement LT. Positive results obtained in this study can further motivate the educational institutes to consider LT as a potential tool for improving the processes. Originality/value This is the first study to develop and validate a framework for structured implementation of LT in the processes of an educational institute. The study is also unique in empirically capturing the impact of LT implementation of an educational institute by analyzing the archived data.

Exploring barriers in lean implementation

2014 ◽  
Vol 5 (2) ◽  
pp. 122-148 ◽  
Author(s):  
Jagdish R. Jadhav ◽  
Shankar S. Mantha ◽  
Santosh B. Rane
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Sector ◽  
Research Work ◽  
Professional Associations ◽  
Literature Survey ◽  
Journal Articles ◽  
Lean Implementation ◽  
Content Type ◽  
Tools And Techniques ◽  
Practical Implications

Purpose – The purpose of this paper is to present an analysis of research on lean focusing on barriers in its implementation through a systematic literature survey. Design/methodology/approach – A literature survey of peer-reviewed journal articles, survey reports, master theses, doctoral theses and paradigmatic books with managerial impact is used as the research methodology. Findings – The findings derived from the evaluation of the publications analyzed have led to the identification of 24 lean barriers. The success of lean implementation will not be entirely based on application of appropriate tools and techniques alone but also on the top managements' involvement and leadership, workers' attitude, resources and the organizational culture. Research limitations/implications – This literature survey is primarily focused on lean implementation in the manufacturing sector. Practical implications – This paper explores barriers for successful lean implementation and provides a concise description of the barriers that will be helpful for further studies in the domain of lean manufacturing. Social implications – Government of many countries around the world is encouraging and helping small- and medium-scale industries to understand and implement lean systems by preparing accessible database of lean consultants, providing financial assistance for training by professionals and establishing professional associations. However, many industries experienced failure in lean implementation. This research work provides a launching pad to develop a strategy to tackle barriers for successful lean implementation. Originality/value – This paper puts forward the key barriers that should be tackled for successful lean implementation. It might represent new opportunities for rigorous and relevant research that would contribute to more translucent knowledge of lean being gained.

The evolution of lean thinking at K-Way: where to next?

2018 ◽  
Vol 8 (1) ◽  
pp. 1-24
Author(s):  
Fatima Hamdulay ◽  
Himanshu Vidhani
Keyword(s):  
Learning Outcomes ◽  
Subject Area ◽  
Waste Reduction ◽  
Executive Education ◽  
Lean Thinking ◽  
Content Type ◽  
Standard Work ◽  
New Challenges ◽  
Under Performing ◽  
A Company

Subject area Lean thinking and organizational culture Study level/applicability MBA, Executive Education, Post Graduate Diploma Case overview The case details the adoption of lean thinking at K-Way, a contemporary technical textile manufacturer of outdoor apparel and accessories. The case covers the 12-year journey at K-Way, detailing the process and cultural improvements the company underwent. The case closes as Bobby, the General Manager at K-Way, thinks about his new challenges. The CEO of K-Way’s parent company, Cape Union Mart, wants Bobby to start devolving the lean thinking approach to other units within Cape Union Mart, in particular a newly acquired and under-performing children’s clothing business. Bobby is excited at the prospect, but simultaneously anxious about the work that still needs to happen at K-Way and more importantly, whether the organization is ready for his, and his key consultant-coach’s withdrawal as the primary “voices” of lean thinking. Would there be a reversal of progress in their absence and how can they counter this? Expected learning outcomes Understanding lean thinking as a management system and not a mere set of tools for waste reduction, while recognizing the importance of waste reduction. An understanding of how to entrench lean thinking in an organization after initial adoption with specific emphasis on the following: Kata and scientific thinking – what it is and how it can be employed; Hoshin Kanri/Strategy Deployment – what it is and how it can be used; Leader Standard Work, what it is and how it can be used. Consider responses for a company that has been on a lean journey for 10 years, with a focus on how (or if) lean leaders can withdraw from the operation. Supplementary materials Teaching Notes are available for educators only. Please contact your library to gain login details or email [email protected] to request teaching notes. Subject code CSS: 9: Operations and logistics

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