A methodology for applying the shop floor management method for sustaining lean manufacturing tools and philosophies: a study of an automotive company in Brazil

2020 ◽  
Vol 11 (6) ◽  
pp. 1233-1252
Author(s):  
Flávio Gaspar ◽  
Fabiano Leal
Keyword(s):  
Lean Manufacturing ◽  
Southeastern Brazil ◽  
Shop Floor ◽  
Application Process ◽  
Content Type ◽  
Practical Applications ◽  
Implementation Model ◽  
Automotive Company ◽  
Practice Opportunities ◽  
Management Method

Purpose The purpose of this paper is to define a method for sustain lean tools and philosophies on a manufacturing environment. Design/methodology/approach An in-depth action research (AR) methodology procedures applied in two cycles were conducted in an automobile company located in southeastern Brazil. The objective is to test the applicability of the shop floor management (SFM) implementation model as presented by Hanenkamp (2013). Findings The SFM model presented by Hanenkamp (2013) has been outlined, detailed and applied in practice. Opportunities for improvement during the application process of this model were verified by changes in its steps. After developing the AR, the authors have shown that the SFM model, as proposed in this paper, can indeed assist managers in applying and maintaining lean manufacturing practices on the shop floor. Originality/value This paper contributes by aiding in filling the gap between practical applications and the sustainability of lean manufacturing concepts and solutions. Furthermore, the guidelines introduced serve as a benchmark for other companies interested in the topic.

RFID impacts on barriers affecting lean manufacturing

2016 ◽  
Vol 116 (8) ◽  
pp. 1585-1616 ◽  
Author(s):  
Muhammad Zeeshan Rafique ◽  
Mohd Nizam Ab Rahman ◽  
Nizaroyani Saibani ◽  
Norhana Arsad ◽  
Waqar Saadat
Keyword(s):  
Literature Review ◽  
Inventory Control ◽  
Systematic Literature Review ◽  
Lean Manufacturing ◽  
Shop Floor ◽  
Lead Times ◽  
Top Management ◽  
Rfid Technology ◽  
Lean Implementation ◽  
Content Type

Purpose Lean manufacturing is one of the leading paradigms for fast and proficient manufacturing but its proper implementation is a foremost task due to certain barriers affecting lean and can be handled when utilized with RFID technology. With this aspect in view, the purpose of this paper is to enlighten and present a thorough literature study that can show how RFID-based lean manufacturing is helpful for handling barriers affecting lean manufacturing in light of previous literature available. Design/methodology/approach In order to achieve this purpose a systematic literature review is conducted to justify the impacts of RFID technology for handling barriers. The aim of this systematic literature review is to initially find the barriers affecting lean implementation and then to explain the properties of RFID-based lean manufacturing which are highly feasible to handle detected barriers. Findings An interrelation is generated in this study which provides a clear indication that the properties of RFID carry significant effects to handle detected barriers in the operational, managerial and financial regime of manufacturing companies. The detected barriers that affect lean implementation are company’s cultures, top management commitment, poor employee administration, lack of finances, unbalanced inventory control, unstable customer handling and longer lead times. The properties of RFID-based lean manufacturing like operational visibility, inventory control, production control, minimized lead times and the real-time data information (to facilitate top management and employees on shop floor) are extremely helpful to control these barriers. Originality/value The originality of this study is the provision of clarity provided to both academicians and practitioners by citing and utilizing previous research studies which undoubtedly indicates positive impacts of RFID on lean implementation.

A conceptual examination of Lean, Six Sigma and Lean Six Sigma models for managing waste in manufacturing SMEs

2020 ◽  
Vol 17 (1) ◽  
pp. 20-32 ◽  
Author(s):  
Harsimran Singh Sodhi ◽  
Doordarshi Singh ◽  
Bikram Jit Singh
Keyword(s):  
Six Sigma ◽  
Lean Manufacturing ◽  
Lean Six Sigma ◽  
Shop Floor ◽  
Content Type ◽  
Manufactured Products ◽  
Manufacturing Organizations ◽  
Scrap Reduction ◽  
Manufacturing Organization

Purpose The purpose of this paper is to examine and evaluate various Lean, Six Sigma and Lean Six Sigma (LSS) models proposed by various researchers, which have been implemented in manufacturing organizations. Design/methodology/approach The present study has followed three major steps in methodology. In the first step, pooling of various research articles has been done, followed by development of the primary results. At the final step, analysis and development of the LSS model have been performed. Findings This paper evaluated and examined various models of Lean Manufacturing, Six Sigma and LSS and developed an advanced LSS model that can be deployed in any manufacturing organization with the purpose of scrap reduction. Originality/value The findings of this study will assist shop floor managers to implement an LSS model in their organizations, which can effectively reduce the waste and enhance the overall productivity and quality of the manufactured products.

Application of lean manufacturing concept for redesigning facilities layout in Indonesian home-food industry

2019 ◽  
Vol 31 (5) ◽  
pp. 815-830 ◽  
Author(s):  
Nilda Tri Putri ◽  
Lora Seprima Dona
Keyword(s):  
Production Process ◽  
Lean Manufacturing ◽  
Food Industry ◽  
Facility Layout ◽  
Added Value ◽  
Actual Condition ◽  
Shop Floor ◽  
Content Type ◽  
Home Food ◽  
The Common

Purpose The purpose of this paper is to redesign the layout of production floor by considering lean manufacturing in order to eliminate the waste and using Block Layout Overview with Layout Planning (BLOCPLAN) algorithm to attain new layout of facilities in Indonesian home-food industry. Design/methodology/approach The common problems that might be appearing in home-food industry, especially in the developing countries like Indonesia are unstandardized production process and unorganized work environment which could produce the waste. One of many solutions to handle this problem is improving the work area (work station) in production floor by rearranging and designing standard operating procedure (SOP) by using lean manufacturing concept. The initial data to minimize the waste is motion time study (data) to identify production standard time. The next step is identifying the common waste(s). Meanwhile, the production floor layout used in this research is designed by using BLOCPLAN algorithm. Findings The recommendation of shop floor facility layout is based on identified waste, which is excess transportation. Subsequently, standard operational procedure (SOP) is developed to support the recommended facility layout as the reference for cookie production process so it can minimize the waste. Research limitations/implications Lean concept is one of method that is widely implemented to reduce the occurrence of defective products and waste that do not provide added value. Based on previous researches, it was found that the concept of lean manufacturing can be applied in various types of service and manufacturing industries, both large companies and small and medium enterprises. Home-food industry competition nowadays is getting intense. This condition makes the stakeholders (of home-food industry, especially in Indonesia) need high performance and productivity to keep their business stable in winning the competition. The new layout can reduce the disadvantages of actual condition. Practical implications This research is useful for small- and medium-sized enterprises (SMEs) in Indonesia especially for home-food industry. The BLOCPLAN layout (as the recommendation) has displacement moment with reduction of 40 percent. Social implications This research believed that it can help SMEs improve their productivity in producing cake and cookies in terms of better layout which can reduce worker movement and standardized working procedure. The design of the production facility layout is a method used to rearrange the production process area so that the distance between processes can be minimized. SOPs was provided as the direction and supervision of workers to work according to standards. Originality/value SOP design can support recommended layout as the reference on making the cake (product) to eliminate wastes, which are motion/movement (alternating in production process flow) and long waiting time due to process delays.

Lean machine manufacturing at Munjal Showa limited

2014 ◽  
Vol 63 (5) ◽  
pp. 644-664 ◽  
Author(s):  
Shivdasini Singh Amin ◽  
Rakesh Atre ◽  
Ankur Vardia ◽  
Boby Sebastian
Keyword(s):  
Cycle Time ◽  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Low Cost ◽  
Shop Floor ◽  
New Approach ◽  
Content Type ◽  
Indigenous Development ◽  
Depth Study ◽  
Increase Productivity

Purpose – The global manufacturing industry is becoming more competitive. Munjal Showa, a shock absorber manufacturer in India, is using indigenous development of lean machines by incorporating concepts of lean manufacturing and low-cost automation techniques to increase their competitiveness. This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time. The purpose of this paper is to offer an in depth study of how at Munjal Showa Ltd lean machines are being developed and manufactured. This paper explores how a cumbersome machine was transformed into a lean machine. Design/methodology/approach – This paper explores how a cumbersome machine was transformed into a lean machine. Findings – This new approach has helped the company to reduce cost of manufacturing and to increase productivity by reducing cycle time and down time. Research limitations/implications – The paper discusses the process of converting one cumbersome machine to a lean machine. Practical implications – Creativity before capital. In lean, team brainstorming of ideas and solutions is emphasized instead of spending large sums of money on capital expenditures Social implications – The cockpit model eases pressure of incumbents on the shop floor. Originality/value – The concepts espoused in the paper has increased productivity by 3.45 times and reduced costs.

Assessing lean implementation and benefits within Indian automotive component manufacturing SMEs

2020 ◽  
Vol 27 (3) ◽  
pp. 1042-1084 ◽  
Author(s):  
Saumyaranjan Sahoo
Keyword(s):  
Lean Manufacturing ◽  
Manufacturing Industry ◽  
Management Practices ◽  
Manufacturing Sector ◽  
Shop Floor ◽  
Automotive Component ◽  
Content Type ◽  
Study Approach ◽  
The Status ◽  
Component Manufacturing

PurposeThe purpose of this paper is to investigate the status of lean manufacturing in Indian automotive sector, component manufacturing industries in terms of lean adoption, benefits, motivation, and challenges of implementing lean manufacturing practices.Design/methodology/approachThe research objectives were achieved by conducting a qualitative multicase study approach. Fourteen Indian automotive component manufacturing small and medium-sized enterprises (SMEs) were chosen based on their different product offerings as well as differing approaches to the introduction and implementation of lean initiatives. Data were collected through in-depth, semistructured interviews supported by shop-floor observations.FindingsThe findings from the present study suggest that some of the participating automotive component manufacturing SMEs have a relatively good understanding of lean concepts and philosophy. However, there is room for further improvement for most SMEs. Major top five lean practices being implemented were found to be cellular manufacturing, total productive maintenance, 5S, work standardization, and quality management practices. Also, leadership and organizational culture were found to be crucial factors for the success of lean manufacturing.Research limitations/implicationsThe fact that the data collected for the research study is based on subjective business evidence obtained from company representatives comprises the main limitation of the present study. So, the results should be considered with caution, as far as the lean adoption in Indian automotive component manufacturing sector is concerned.Practical implicationsBased on the present study, suggestions can be made regarding the successful adoption of lean principles, not only for the participating SMEs but also for the whole of the automotive component manufacturing sector. More specifically, by determining the strength and weakness of automotive component manufacturing SME's effort to adopt lean, suitable managerial initiatives can be undertaken by these companies as well as the whole sector to fully adopt lean and derive the respective benefits.Originality/valueThis paper explores the status of lean adoption in Indian automotive component manufacturing SMEs. Considering the unique characteristics of the automotive component manufacturing industry, the present research would be helpful for making strategies to implement lean in automotive component manufacturing industry setups.

Productivity gains through standardization-of-work in a manufacturing company

2019 ◽  
Vol 30 (6) ◽  
pp. 899-919 ◽  
Author(s):  
Rahul S. Mor ◽  
Arvind Bhardwaj ◽  
Sarbjit Singh ◽  
Anish Sachdeva
Keyword(s):  
Operations Management ◽  
Lean Manufacturing ◽  
High Performance ◽  
Continuous Process ◽  
Shop Floor ◽  
Productivity Analysis ◽  
Content Type ◽  
Work Shift ◽  
Manufacturing Company ◽  
Productivity Gains

Purpose The purpose of this paper is to identify the non-value-adding activities (NVAs) of core making process and to eliminate them through the standardization-of-work (SW) procedures in a manufacturing company. Design/methodology/approach The action-research methodology was adopted for the current study. First, various lean tools were identified through literature review, and the bottleneck area was identified in discussion with the shop-floor executives. NVAs were recorded after a continuous process study including method study and motion analysis followed by the standard operating procedure. Second, the standardized work combination tables were prepared and NVAs were eliminated using the SW procedures. SW has been opted because it is a set of actions which helps in analyzing, improving and controlling the process and it leads to continual improvement. Findings The production logbook revealed that the capacity in this particular workstation was 54 pieces per 7 h work shift against the current production of approx. 45–50 pieces (past data). SW saved 31.6 s per cycle which boosted the production up to 58 pieces per 7 h work shift. Finally, the authors came to know that the productivity of this particular process increased up to 6.5 percent which may upsurge if this action is executed continually with the support from shop-floor executives and management. These results were also compared with previous research works in this area and found significant relevance, and hence, the results appear to be reliable. Research limitations/implications This is a unique study in itself which explores the lean model by assessing NVAs of core making process. The proposed approach needs to be tested across different other core making processes of the case company so as to generalize the effectiveness of SW as well as the results obtained in the current study. Practical implications The current study illustrates an important step to give more visibility to the lean concept by addressing the problem of lack of standard procedures. This study will help the shop-floor executives and managers to focus their efforts in achieving high performance through effective implementation of SW. The study should be of the interest of researchers in the area of lean manufacturing, operations management, productivity analysis, etc. Originality/value The findings of this study are based on the problem formulation for productivity gains using SW procedures in the case company. The study introduces a new perspective for the execution of SW for core making processes. SW created transparency in workflow, enhanced the safety and eliminated the 3Ms. The outcome of the current study was discussed with the production team and management of the company to validate the productivity gains and received an optimistic response. Most importantly, these improvements were achieved with no investment in machinery or tooling.

Good problem solvers? Leveraging knowledge sharing mechanisms and management support

2019 ◽  
Vol 23 (6) ◽  
pp. 1017-1038 ◽  
Author(s):  
Ambra Galeazzo ◽  
Andrea Furlan
Keyword(s):  
Transformational Leadership ◽  
Problem Solving ◽  
Knowledge Sharing ◽  
Hierarchical Linear Modeling ◽  
Shop Floor ◽  
Management Support ◽  
Linear Modeling ◽  
Content Type ◽  
Problem Solvers ◽  
Good Problem

Purpose Organizational learning relies on problem-solving as a way to generate new knowledge. Good problem solvers should adopt a problem-solving orientation (PSO) that analyzes the causes of problems to arrive at an effective solution. The purpose of this paper is to investigate this relevant, though underexplored, topic by examining two important antecedents of PSO: knowledge sharing mechanisms and transformational leaders’ support. Design/methodology/approach Hierarchical linear modeling analyses were performed on a sample of 131 workers in 12 plants. A questionnaire was designed to collect data from shop-floor employees. Knowledge sharing was measured using the mechanisms of participative practices and standardized practices. Management support was assessed based on the extent to which supervisors engaged in transformational leadership. Findings Knowledge sharing mechanisms are an antecedent of PSO behavior, but management support measured in terms of transformational leadership is not. However, transformational leadership affects the use of knowledge sharing mechanisms that, in turn, is positively related to PSO behavior. Practical implications The research provides practical guidance for practitioners to understand how to manage knowledge in the workplace to promote employees’ PSO behaviors. Originality/value Though problem-solving activities are intrinsic in any working context, PSO is still very much underrepresented and scarcely understood in knowledge management studies. This study fills this gap by investigating the antecedents of PSO behavior.

scholarly journals Operations management body of knowledge and its relevance to manufacturing and service organizations

2018 ◽  
Vol 25 (4) ◽  
pp. 373-389 ◽  
Author(s):  
Jurandir Peinado ◽  
Alexandre Reis Graeml ◽  
Fernando Vianna
Keyword(s):  
Operations Management ◽  
Lean Manufacturing ◽  
Process Management ◽  
Work Organization ◽  
The Body ◽  
Service Organizations ◽  
Manufacturing Companies ◽  
Content Type ◽  
Service Companies ◽  
Body Of Knowledge

Purpose The purpose of this paper is to assess the differences in importance assigned by manufacturing or service organizations to topics related to operations management and its attendant body of knowledge. Design/methodology/approach The authors did this by cataloguing and analyzing vacancy announcements related to operations management, presented by manufacturing and services companies in major Brazilian human resources websites. Findings The results show that manufacturing companies primarily hire personnel with skills in routine process management, quality management, lean manufacturing, ergonomics and work organization. Service companies generally seek professionals with knowledge and experience in logistics, supply chain management and project management. Research limitations/implications This study presents some limitations that reduce the power of its conclusions. There is some degree of subjectivity in the interpretation of the contents of the analyzed ads. In order to reduce this problem, the authors who did the tabulation of data marked the situations for which there were some doubts about the classification, discussing them with the other author, until they reached a consensus on the best way to classify each one. Originality/value The discussion about the importance assigned by manufacturing and service companies to the topics of operations management is crucial for not only the results obtained, but also to stimulate the debate on topics that comprise or should comprise the body of knowledge of operations management, and the way they are incorporated into business practice. This provides an additional opportunity to reflect on the potential of operations management in supporting business managers now and in the future.

Zn diffusion and reflow behaviour of Sn-9Zn and Sn-8.5Zn-0.5Ag-0.01Al-0.1Ga solders on a Ni/Cu substrate under IR reflow

2014 ◽  
Vol 26 (2) ◽  
pp. 87-95 ◽  
Author(s):  
J. Mittal ◽  
K.L. Lin
Keyword(s):  
Theoretical Calculations ◽  
Research Work ◽  
Content Type ◽  
Diffusion Behavior ◽  
Zn Diffusion ◽  
Cu Substrate ◽  
Practical Applications ◽  
Substrate Interface ◽  
Solder Balls ◽  
Practical Implications

Purpose – This paper aims to compare the reflow and Zn diffusion behaviors in Sn-Zn and Sn-8.5Zn-0.5Ag-0.01Al-0.1Ga (5E) solders during soldering on a Ni/Cu substrate under infrared (IR) reflow. The study proposes a model on the effect of various elements particularly Zn diffusion behavior in the solders on the formation of intermetallic compounds (IMCs). Design/methodology/approach – The melting activities of two solders near their melting points on copper substrates are visualized in an IR reflow furnace. Reflowed solder joints were analyzed using scanning electron microscope and energy dispersive X-ray spectroscopy. Findings – Reflow behaviors of the solders are similar. During melting, solder balls are first merged into each other and then reflow on the substrate from top to bottom. Both solders show a reduced amount of Zn in the solder. Theoretical calculations demonstrate a higher Zn diffusion in the 5E solder; however, the amount of Zn actually observed at the solder/substrate interface is lower than Sn-9Zn solder due to the formation of ZnAg3 in the solder. A thinner IMC layer is formed at the interface in the 5E solder than the Sn-Zn solder. Research limitations/implications – The present work compares the 5E solder only with Sn-Zn solder. Additional research work may be required to compare 5E solder with other solders like Sn-Ag, SnAgCu, etc. to further establish its practical applications. Practical implications – The study ascertains the advantages of 5E solder over Sn-Zn solder for all practical applications. Originality/value – The significance of this paper is the understanding of the relation between reflow behavior of solders and reactivity of different elements in the solder alloys and substrate to form various IMCs and their influence on the formation of IMC layer at solder/substrate interface. Emphasis is provided for the diffusion behavior of Zn during reflow and respective reaction mechanisms.

Application of lean practices in small and medium-sized food enterprises

2013 ◽  
Vol 116 (1) ◽  
pp. 125-141 ◽  
Author(s):  
Manoj Dora ◽  
Dirk Van Goubergen ◽  
Maneesh Kumar ◽  
Adrienn Molnar ◽  
Xavier Gellynck
Keyword(s):  
Food Processing ◽  
Lean Manufacturing ◽  
Raw Materials ◽  
Current Status ◽  
Food Sector ◽  
Statistical Process ◽  
Content Type ◽  
Lean Practices ◽  
The Status ◽  
Manufacturing Techniques

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.

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