Design framework for a lean warehouse – a case study-based approach

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
P. Raghuram ◽  
Mahesh Kumar Arjunan
Keyword(s):  
Inventory Management ◽  
Material Handling ◽  
Flow Characteristics ◽  
Design Procedure ◽  
Resource Planning ◽  
Content Type ◽  
Factors Affecting ◽  
Lean Principles ◽  
Warehouse Design

PurposeThis purpose of this study is to develop a simple framework for designing a warehouse incorporating lean principles. Multiple objectives like resource planning, material handling, storage, inventory management, including internal and external logistics, are considered.Design/methodology/approachA design procedure to incorporate lean principles for designing a warehouse for a complex multi-model production line has been proposed. The preferred standards and factors affecting warehouse design, the inputs and outputs of process flow characteristics, are incorporated into the design. Current and future state value stream mappings are drawn to bring out the challenges in the value flow.FindingsThe framework for designing a lean warehouse have been implemented and validated in a heavy machinery manufacturer. This framework will ease the work of the future lean-based warehouse designers to apply simple step-by-step processes to achieve the goal with the nearest accuracy. The steps followed can be summarized as defining the lean processes, making the lean process as the design base, collecting inputs like stock-keeping unit master, inventory and space details, and building the lean warehouse design with the step-by-step processes.Practical implicationsPractical tips on warehouse design have been explained focusing on the part volume, quantity handled, inventory and throughput. This will assist the practitioners in designing a lean warehouse and leading to an improved operational performance.Originality/valueA simplified design procedure for designing a lean warehouse, along with a real-time case study has been enumerated in detail. Effective use of space and resources with lean tools and techniques lead to better storage and picking efficiency resulting in an overall reduction in cost.

A systematic literature review of healthcare supply chain and implications of future research

2019 ◽  
Vol 13 (4) ◽  
pp. 405-435 ◽  
Author(s):  
Anuj Dixit ◽  
Srikanta Routroy ◽  
Sunil Kumar Dubey
Keyword(s):  
Supply Chain ◽  
Literature Review ◽  
Inventory Management ◽  
Cold Chain ◽  
Future Research ◽  
Research Papers ◽  
Content Type ◽  
Drug Manufacturing ◽  
Customer Training

Purpose This paper aims to review the healthcare supply chain (HSC) literature along various areas and to find out the gap in it. Design/methodology/approach In total, 143 research papers were reviewed during 1996-2017. A critical review was carried out in various dimensions such as research methodologies/data collection method (empirical, case study and literature review) and inquiry mode of research methodology (qualitative, quantitative and mixed), country-specific, targeted area, research aim and year of publication. Findings Supply chain (SC) operations, performance measurement, inventory management, lean and agile operation, and use of information technology were well studied and analyzed, however, employee and customer training, tracking and visibility of medicines, cold chain management, human resource practices, risk management and waste management are felt to be important areas but not much attention were made in this direction. Research limitations/implications Mainly drug and vaccine SC were considered in current study of HSC while SC along healthcare equipment and machine, hospitality and drug manufacturing related papers were excluded in this study. Practical implications This literature review has recognized and analyzed various issues relevant to HSC and shows the direction for future research to develop an efficient and effective HSC. Originality/value The insight of various aspects of HSC was explored in general for better and deeper understanding of it for designing of an efficient and competent HSC. The outcomes of the study may form a basis to decide direction of future research.

Engaging professionals with serious games: the Lean Healthcare Lab at Siena University Hospital

2017 ◽  
Vol 31 (3) ◽  
pp. 7-10 ◽  
Author(s):  
Federico Barnabè ◽  
Maria Cleofe Giorgino ◽  
Jacopo Guercini ◽  
Caterina Bianciardi ◽  
Vincenzo Mezzatesta
Keyword(s):  
Serious Games ◽  
Leadership Skills ◽  
University Hospital ◽  
Management Tools ◽  
Lean Thinking ◽  
Content Type ◽  
Lean Principles ◽  
Lean Healthcare ◽  
Firsthand Experience

Purpose This paper aims to stimulate interest in the potentials of serious games within organizations. Through the examination of a case study, emphasis is given to serious games designed for health care (HC) organizations that are adopting lean thinking principles and tools. Design/methodology/approach The paper discusses how serious games can be designed and implemented in practice by describing a case study based on a HC organization. The program, now in its second year, has been used extensively to train HC professionals. Findings The article is based on the authors’ firsthand experience with serious games and the outcome of several projects carried out in the HC setting under analysis. Serious games were found to be powerful training and management development tools as well as engaging environments for professionals. Specifically, The Lean Healthcare Lab supported professionals in their use and implementation of several Lean principles and techniques. Research limitations/implications The article suggests the opportunity to evaluate the effectiveness of serious games also to improve team performance and develop leadership skills. Practical implications Serious games have an enormous potential in sustaining processes of both individual and organizational learning, as well as facilitating improved teamwork. Moreover, serious games are very effective educational tools when compared to more conventional programs. Originality/value The approach described in this study can be used to design and implement serious games in any type of organization, in particular, those employing highly skilled professionals. Additionally, this article highlights how serious games can provide learners with a simulated close-to-reality environment where they are challenged to develop policies and use a variety of Lean and management tools.

Towards Chinese smart manufacturing ecosystem in the context of the one belt one road initiative

2018 ◽  
Vol 11 (3) ◽  
pp. 291-310 ◽  
Author(s):  
Rafif Al-Sayed ◽  
Jianhua Yang
Keyword(s):  
Industrial Revolution ◽  
Structured Interview ◽  
Industrial Clusters ◽  
Added Value ◽  
Smart Manufacturing ◽  
Content Type ◽  
Factors Affecting ◽  
Industrial Sectors ◽  
Regional Collaboration

Purpose The purpose of this paper is to examine empirically China’s determined thrust to attain a high level of technological innovation and the factors affecting moving towards a smart and sophisticated manufacturing ecosystem in conjunction with the Belt and Road Initiative (OBOR). Design/methodology/approach This research provides empirical determination of the factors affecting moving towards smart manufacturing ecosystems in China. The method is based on combining two approaches: semi-structured interview and questionnaire-based with academics, experts and managers in various Chinese industrial sectors. The results are based on the multivariate analysis of the collected data. A case study of the current manufacturing ecosystem was also analyzed, in order to understand the present state as well as the potential for China’s competitive edge in the developed OBOR countries. Findings The results illustrate the importance of the infrastructure dimension comprising variables related to ecosystems, industrial clusters and Internet of Things IoT and other advanced technologies. A case study of the city of Shenzhen’s transformation into a smart cluster for innovative manufacturing points out how China’s OBOR initiative for regional collaboration will further transform the regional smart clusters into an ultra-large innovation based smart ecosystem. Originality/value This research is the first to study China’ policies towards playing a prominent role in the Fourth Industrial Revolution 4IR in the context of the OBOR initiative, through empirically defining the factors affecting moving towards a knowledge-intensive smart manufacturing ecosystem where the added value is mostly innovation based.

Inventory Management, a Decision Support Framework to Improve Operational Performance

2012 ◽  
pp. 581-600
Author(s):  
Jan van den Berg ◽  
Guido van Heck ◽  
Mohsen Davarynejad ◽  
Ron van Duin
Keyword(s):  
Supply Chain ◽  
Decision Support ◽  
Inventory Management ◽  
Enterprise Resource Planning ◽  
Resource Planning ◽  
Performance Improvements ◽  
Decision Support Framework ◽  
Comparable Performance ◽  
Potential Benefits

Enterprise Resource Planning systems have been introduced to support the efficient and effective execution of business processes. In practice, this may not fully succeed. This also holds in particular for inventory management (IM), which forms a part of supply chain management. Within this research, by analyzing the IM business process theoretically, eleven potential benefits are indicated. Next, by using a Business Intelligence approach, key performance indicators (KPIs) are selected to measure the performance of IM sub-processes. Integration of these approaches yields an IM performance decision support framework that can be used to obtain a generic, coherent picture of the fundamental IM processes in an organization. In addition, by tracking and analyzing KPI measurements, adequate decisions can be prepared towards the improvement of the operational IM performance. The proposed framework is validated using experts’ opinions and a comparative case study. The experts’ comments yielded a list of top-10 KPIs, based on the measurements of which a set of quick wins can be determined. The case study results show that some of the identified potential benefits are also observed in practice. Future research may reveal that comparable performance improvements are possible in other IM environments (and even in other supply chain domains) based on similar decision support frameworks.

Corporate survival in Industry 4.0 era: the enabling role of lean-digitized manufacturing

2019 ◽  
Vol 31 (1) ◽  
pp. 1-30 ◽  
Author(s):  
Morteza Ghobakhloo ◽  
Masood Fathi
Keyword(s):  
Enterprise Resource Planning ◽  
Industry 4.0 ◽  
Manufacturing System ◽  
Resource Planning ◽  
Security And Privacy ◽  
Social Implications ◽  
Future Research ◽  
Manufacturing Firm ◽  
Content Type

Purpose The purpose of this paper is to demonstrate how small manufacturing firms can leverage their Information Technology (IT) resources to develop the lean-digitized manufacturing system that offers sustained competitiveness in the Industry 4.0 era. Design/methodology/approach The study performs an in-depth five years case study of a manufacturing firm, and reports its journey from failure in the implementation of enterprise resource planning to its success in integrating IT-based technology trends of Industry 4.0 with the firm’s core capabilities and competencies while pursuing manufacturing digitization. Findings Industry 4.0 transition requires the organizational integration of many IT-based modern technologies and the digitization of entire value chains. However, Industry 4.0 transition for smaller manufacturers can begin with digitization of certain areas of operations in support of organizational core strategies. The development of lean-digitized manufacturing system is a viable business strategy for corporate survivability in the Industry 4.0 setting. Research limitations/implications Although the implementation of lean-digitized manufacturing system is costly and challenging, this manufacturing strategy offers superior corporate competitiveness in the long run. Since this finding is rather limited to the present case study, assessing the business value of lean-digitized manufacturing system in a larger scale research context would be an interesting avenue for future research. Practical implications Industry 4.0 transition for typical manufacturers should commensurate with their organizational, operational and technical particularities. Digitization of certain operations and processes, when aligned with the firm’s core strategies, capabilities and procedures, can offer superior competitiveness even in Industry 4.0 era, meaning that the strategic plan for successful Industry 4.0 transition is idiosyncratic to each particular manufacturer. Social implications Manufacturing digitization can have deep social implications as it alters inter- and intra-organizational relationships, causes unemployment among low-skilled workforce, and raises data security and privacy concerns. Manufacturers should take responsibility for their digitization process and steer it in a direction that simultaneously safeguards economic, social and environmental sustainability. Originality/value The strategic roadmap devised and employed by the case company for managing its digitization process can better reveal what manufacturing digitization, mandated by Industry 4.0, might require of typical manufacturers, and further enable them to better facilitate their digital transformation process.

Digitizing the field: designing ERP systems for Triple-A humanitarian supply chains

2020 ◽  
Vol 10 (2) ◽  
pp. 231-260
Author(s):  
Ioanna Falagara Sigala ◽  
William J. Kettinger ◽  
Tina Wakolbinger
Keyword(s):  
Supply Chain ◽  
Level Structure ◽  
Resource Planning ◽  
Design Principles ◽  
Erp Systems ◽  
Content Type ◽  
Humanitarian Operations ◽  
Humanitarian Organizations ◽  
Embedded Case Study

PurposeThe purpose of this study is to explore what design principles need to be considered in Enterprise Resource Planning (ERP) systems for humanitarian organizations (HOs) to enable agile, adaptive and aligned (Triple-A) humanitarian supply chain capabilities and digitize humanitarian operations.Design/methodology/approachThis study follows an embedded case study approach with a humanitarian medical relief organization, Médecins Sans Frontières (MSF), which engaged in a multiyear ERP design at its humanitarian field missions.FindingsThis research shows that ERP systems for humanitarian organizations should be designed as unique systems addressing humanitarian organizations' challenges and unique missions, their value generation processes, and resource base in an effort to improve organizational performance. This study presents 12 general design principles that are unique for humanitarian organizations. These design principles provide a high-level structure of guidance under which specific requirements can be further defined and engineered to achieve success.Research limitations/implicationsThe results of this study are based on a single case study limiting generalizability. However, the case study was analyzed and presented as an embedded case study with five autonomous subunits using different business processes and following different adoption and implementation approaches. Therefore, the findings are derived based on considerable variance reflective of humanitarian organizations beyond MSF.Practical implicationsThis study recognizes that HOs have unique routines that standard commercial ERP packages do not address easily at the field level. The primary contribution of this research is a set of design principles that consider these unique routines and guide ERP development in practice. National and international HOs that are planning to implement information systems, private companies that are trading partners of HOs as well as vendors of ERP systems that are looking for new opportunities would all benefit from this research.Originality/valueThis study fills the gap in the humanitarian literature regarding the design of ERP systems for humanitarian organizations that enable Triple–A supply chain capabilities and it advances the knowledge of the challenges of ERP design by HOs in the context of humanitarian operations.

A practical integrated solution into enterprise application: a large-scale quality control system development case study

2020 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Vahid Hajipour ◽  
Hamidreza Amouzegar ◽  
Sajjad Jalali
Keyword(s):  
Quality Control ◽  
Enterprise Resource Planning ◽  
Large Scale ◽  
Resource Planning ◽  
Qualitative Assessment ◽  
Primary Concern ◽  
Content Type ◽  
Business Units ◽  
Functional Units

PurposeEnterprise resource planning (ERP) offers a streamlined system architecture to feed businesses with beneficial information in the current intense global competition. The primary concern of ERP is how to integrate different functional units to facilitate a unified flow of information. This paper aims at providing a non-trivial practice of integrating the quality control (QC) system into the core ERP processes of a real large-scaled case study.Design/methodology/approachTo satisfy the purpose of the current study, a large-scale steel making holding, inclusive of 27 business units being dispersed over a wide area, has been targeted. In our research methodology, a sample of four business units is selected as the pilot cases to be investigated at first. The output results of such investigations are further extended to the other units. In light of the investigation, the existing QC working conditions of the pilot cases are assessed through the As-Is model. The To-Be models are derived based on the best practices and the integration scope is then bordered.FindingsThe findings show that the integrated QC solution has enabled the following features: the smooth interconnection between QC and other functional units like purchase and manufacturing, the ease of generating real-time performance report of QC unit, the sack of tracing the quality of any available item in the system and the root-cause of defects, and the straightforwardness of the qualitative assessment of the suppliers.Research limitations/implicationsThere is almost no similar practice for designing a large-sized integrated system from scratch in the target region associated with our case study while the off-the-shelf products are prohibitively expensive.Practical implicationsThis paper includes implications for providing a standard practice on integrating a substantial module of ERP down to the smallest detail.Originality/valueThe value of the current paper is associated with fulfilling a critical research gap in the context of studying the QC integration into an enterprise solution. In fact, despite the importance of the QC module and its plethora of interconnection with other functional units, the literature review shows a centric lack of considering such integration in a real case study, particularly the large-scale one. Further, this paper works as a valuable study in the literature owing to not only focusing on the design and development of an integrated QC solution but also considering the deployment facet of such a practice.

Leaning into sustainability at University of Alberta Libraries

2016 ◽  
Vol 37 (3) ◽  
pp. 136-148 ◽  
Author(s):  
Gerald Beasley ◽  
Trish Rosseel
Keyword(s):  
Design Methodology ◽  
Academic Library ◽  
Building Design ◽  
Library Services ◽  
Staff Time ◽  
Content Type ◽  
Lean Principles ◽  
University Of Alberta ◽  
Staffing Model

Purpose – The purpose of this paper is to present a case study that considers the links between cost avoidance, lean design, and sustainability in relation to two different library projects at University of Alberta Libraries (UAL) – the design of the Research and Collections Resource Facility and the development of new fee-based library services at UAL’s John W. Scott Health Sciences Library. Design/methodology/approach – This case study describes the analysis of each project’s workflows in relation to lean design in order to enhance processes and service delivery. Findings – Findings to date in both of these ongoing projects suggest that consideration of the lean philosophy has already led to process and service improvements. With regard to the new building design project, revised task design is already resulting in significant savings in staff time, and work space. And the staffing model for fee-based specialized services has already been redesigned, an alignment with lean principles. Research limitations/implications – While this paper does discuss and define lean design, it does not provide a comprehensive summary of research in this area. Originality/value – This paper highlights the value of lean design as a framework for designing, developing, and reviewing academic library buildings, services, processes, and workflows to ensure they are sustainable.

Capture and evaluation of innovative ideas in early stages of product development

2019 ◽  
Vol 31 (6) ◽  
pp. 908-927 ◽  
Author(s):  
Peter Madzík
Keyword(s):  
Product Development ◽  
Innovation Process ◽  
Kano Model ◽  
Effect Analysis ◽  
Content Type ◽  
Factors Affecting ◽  
Early Stages ◽  
Structured Analysis ◽  
Idea Evaluation

Purpose The purpose of this paper is to propose a structured procedure for the capture and evaluation of innovative ideas in the early stages of product development. The procedure is designed to take account of internal and external factors affecting the value of innovative ideas. Design/methodology/approach The proposed procedure is based on divergent and convergent approaches to innovation. Ideas are generated and captured using targeted questions and subsequently evaluated using modifications of the Kano model and failure mode and effect analysis (FMEA). Idea evaluation considers four criteria – delight, originality, market share potential and simplicity – which are used to compute an “idea priority number”. Findings A case study looking at innovations in swimming goggles verified the validity of the proposed procedure. The procedure also supports fact-based decision making and applies a structured perspective to the innovation process that makes it easier to manage. Research limitations/implications The case study made use of a pilot survey in which 32 customers participated. Although the case study was only intended as a demonstration of the method’s use, such a sample size could lead to unreliable results in certain cases. Originality/value Applications of standard or expanded FMEA do not add value to a product because the main purpose of the approach is to prevent failure. The proposed inversion of FMEA logic combined with customer view via the Kano model offers a method for the structured analysis of product innovations. No similar approach to the evaluation of innovations has so far appeared in the literature.

Sign in / Sign up

Export Citation Format

Share Document