Exploring How Lean Product and Process Development Can Promote Industrial Sustainability

2021 ◽  
Author(s):  
Daniel R. Cooper ◽  
Katrina Appell
Keyword(s):  
Case Studies ◽  
Manufacturing Industry ◽  
Process Development ◽  
Sustainable Manufacturing ◽  
Cost Savings ◽  
Environmental Benefits ◽  
Value Stream Mapping ◽  
Structured Interviews ◽  
Organizational System ◽  
Product And Process

Abstract Approximately one-third of anthropogenic greenhouse gas emissions from energy and processing are from making products and chemicals. These emissions can be lowered if they are deliberately considered during the design of products. How can lean product and process development (LPPD) be used to build environmental considerations into the product development system? We explore if LPPD is an effective system in delivering sustainable manufacturing. We conducted case studies in the automotive and oil & gas industries in which LPPD was used to deliver significant physical changes to the product and product manufacturing. We completed semi-structured interviews with stakeholders and focused on the motivation for the change, how LPPD was either a help or hindrance, and the delivered cost savings and environmental benefits. Findings from the case studies were used to structure a workshop on LPPD and sustainability held at a leading manufacturing (industry focused) conference. In this workshop, we focused on first identifying the main environmental impacts in each industry, the physical opportunities to reduce those impacts, and how LPPD might help or hinder delivering that change. This article structures the findings from the case studies and workshop. We present a guide (with examples) for how various LPPD methods (e.g., concept papers, value stream mapping, and design guides) might be used to meet sustainability challenges (e.g., reducing the generation of manufacturing scrap). While LPPD is itself agnostic to sustainability, we suggest that it is an effective method of creating an organizational system for promoting sustainable manufacturing particularly in complex environments.

Lean Product and Process Development and Set-Based Concurrent Engineering in the Dining Industry: the experience of an American-Asian fusion restaurant

2021 ◽  
Vol 16 (3-2020) ◽  
pp. 202-224
Author(s):  
Ronaldo Akiyoshi Nagai ◽  
Alvair Silveira Torres Junior
Keyword(s):  
Action Research ◽  
Operations Management ◽  
Manufacturing Industry ◽  
Process Development ◽  
Innovation Process ◽  
Structured Interviews ◽  
Research Application ◽  
Product And Process ◽  
Process Observation ◽  
Dining Industry

The purpose of this paper is to investigate the implications of a culinary innovation process when adopting manufacturing industry concepts such as LPPD: Lean Product and Process Development. The action research structured in five steps (semi-structured interviews, process mapping, training, and implementation of a new process, process observation, and compilation/feedback of results) allowed the introduction of the LPPD in the culinary innovation process. Results showed that despite the innovation process of a restaurant being based on tacit knowledge, concepts from the manufacturing innovation process could be adopted. Findings can contribute to the multidisciplinary studies involving innovation, the hospitality industry, and the action research application on operations management.

scholarly journals Energy Analysis via Value Stream Mapping: A case study of an Automotive Weld Plant

ORiON ◽  
2021 ◽  
Vol 37 (2) ◽  
Author(s):  
Keshav Ramsunder ◽  
Oludolapo Olanrewaju
Keyword(s):  
Lean Manufacturing ◽  
Sustainable Manufacturing ◽  
Environmental Benefits ◽  
Value Stream Mapping ◽  
Measuring Instruments ◽  
Manufacturing Companies ◽  
Step Method ◽  
Empirical Observation ◽  
Value Stream ◽  
Starting Point

Over the past few decades, Lean Manufacturing (LM) has been the pinnacle of strategies applied for cost and waste reduction. However as the search for competitive advantage and production growth continues, there is a growing consciousness towards environmental preservation. With this consideration in mind this research investigates and applies Value Stream Mapping (VSM) techniques to aid in reducing environmental impacts of manufacturing companies. The research is based on empirical observation within the Chassis weld plant of Company X. The observation focuses on the weld operations and utilizes the cross member line of Auxiliary Cross as a point of study. Using various measuring instruments to capture the emissions emitted by the weld and service equipment, data is collected. The data is thereafter visualised via an Environmental Value Stream Map (EVSM) using a 7-step method. It was found that the total lead-time to build an Auxiliary Cross equates to 16.70 minutes and during this process is emitted. It was additionally found that the UPR x LWR stage of the process indicated both the highest cycle time and carbon emissions emitted and provides a starting point for investigation on emission reduction activity. The EVSM aids in the development of a method that allows quick and comprehensive analysis of energy and material flows. The results of this research are important to practitioners and academics as it provides an extension and further capability of Lean Manufacturing tools. Additionally, the EVSM provides a gateway into realising environmental benefits and sustainable manufacturing through Lean Manufacturing.

scholarly journals Techniques and tools of lean production: multiple case studies in brazilian agribusiness units

2020 ◽  
Vol 27 (1) ◽  
Author(s):  
Eduardo Guilherme Satolo ◽  
Laiz Eritiemi de Moura Hiraga ◽  
Lucas Furlani Zoccal ◽  
Gustavo Antiqueira Goes ◽  
Wagner Luiz Lourenzani ◽  
...  
Keyword(s):  
Case Studies ◽  
Global Economy ◽  
Lean Production ◽  
Customer Relationship ◽  
Value Stream Mapping ◽  
Structured Interviews ◽  
Production Flow ◽  
Implementation Challenges ◽  
Multiple Case ◽  
Multiple Case Studies

Abstract The literature regarding Lean Production philosophy is vast depicting historical aspects, implementation challenges, benefits of its adoption and other topics applied to various industries and services. However, the agribusiness segment, one of the major segments of the global economy features a large gap in national and international literature. This article aims to conduct a research through multiple case studies concerning the use of techniques and tools of Lean Production System in agribusiness organizations. Multiple type case studies were conducted in eight agribusiness units from different segments through the application of structured interviews, on site visits and document analysis. The research carried has identified that Lean Production techniques and tools are applicable to agribusiness environments, and that the ones which involve improvements in process control, production flow and logistics have higher emphasis on research units. Techniques and tools such as long-term supplier and customer relationship, production smoothing/heijunka and value stream mapping distinguished themselves by the similarity of use when compared to previous studies in agribusiness environment. It was also identified that there are differences concerning the adoption of the techniques and tools in research units that operate in production environments of the type Make to Order or Make to Stock. Such differences are imposed by specificities that affect agribusiness organizations, which is indicative for future studies.

scholarly journals Business model and methods of evaluation in sustainable manufacturing

2021 ◽  
Vol 8 ◽  
pp. 28
Author(s):  
Haishang Wu
Keyword(s):  
Business Model ◽  
Manufacturing Industry ◽  
Evaluation Method ◽  
Dominant Role ◽  
Sustainable Manufacturing ◽  
Cost Savings ◽  
Cost Effective ◽  
Divide And Conquer ◽  
Efficient Production ◽  
Home Based

Additive manufacturing (AM) enables cost-effective and efficient production toward sustainability. However, a rigorous evaluation method is required to further investigate the measurement method and efficiency before AM can be well-positioned in sustainable manufacturing and become the industry mainstream. Cost savings play a key role in the manufacturing industry. Compared to conventional manufacturing (CM), the cost of AM is volume-independent. In contrast, CM production requires a certain volume to share the initial tooling costs to achieve cost reduction. This constraint limits CM from service on demand and leaves ambiguity in the threshold setting of that critical batch volume. In addition, the invisibility of AM advantages in cost factors blocks AM technologies from appropriate processes and affects its applications. To address these issues, this paper proposes a business model. The major issues encountered by AM are the scaling, speed, and size of products. The enhancement of cost modeling and addressing speed, scale, and size issues are the novelties of this study and provide a breakthrough in AM issues. Generic equations are derived using the convergence effect and cost–volume intersection calculation between AM and CM. Furthermore, the divide-and-conquer approach is proposed to support scaling factors and dependencies for both AM and CM. Consequently, appropriate AM technologies can be compared with the CM convergence threshold to contribute to decision-making. Next, the advantages and weaknesses of AM are identified, and a collaboration pattern is proposed to connect large enterprises, small-and medium-sized enterprises, and home-based manufacturers into an AM society. Through this society, the advantages of AM can be fully exploited, scaling and speed issues can be addressed, and AM's dominant role in sustainable manufacturing can be made feasible.

scholarly journals Impact of Energy Measurements in Machining Operations

2010 ◽  
Author(s):  
Minna Lanz ◽  
Mahesh Mani ◽  
Swee Leong ◽  
Kevin Lyons ◽  
Ari Ranta ◽  
...  
Keyword(s):  
Case Studies ◽  
Energy Savings ◽  
Sustainable Manufacturing ◽  
Cost Savings ◽  
Performance Outcomes ◽  
Cnc Machining ◽  
Numerical Control ◽  
Main Question ◽  
Potential Cost ◽  
The Impact

Over the past years, institutions in general are increasingly interested and involved in sustainability and social responsibility. In addition, social and political pressures have led to the creation of new regulations and policies that support new business opportunities around global sustainability. Considering sustainable manufacturing, a number of indicators have been proposed and currently being researched. The aim of this paper is to explore and discuss the impact of energy measurements as an indicator for sustainable manufacturing. The main question to be asked is, can energy measurement be used for optimization the machining level process. Based on energy monitoring during two Computer Numerical Control (CNC) machining case studies, the significance of energy cost based on different CNC machining strategies and parameter settings is examined and discussed. The preliminary results from the energy measurements on the case studies indicate that potential cost savings in energy will be minimal in CNC operations. Based on the case studies, the potential energy savings in monetary value do not necessarily justify a company’s investment in implementing real time energy tracking technologies; however the results were limited in scope with regards measuring energy as an indicator for evaluating other performance outcomes.

The three dimensions of strategic flexibility

2021 ◽  
Vol ahead-of-print (ahead-of-print) ◽  
Author(s):  
Fabian Hoeft
Keyword(s):  
Conceptual Model ◽  
Case Studies ◽  
Firm Strategy ◽  
Three Dimensions ◽  
Strategic Flexibility ◽  
Structured Interviews ◽  
Content Type ◽  
Holistic Understanding ◽  
Product And Process ◽  
High Level

Purpose Strategic flexibility is a widely discussed concept. Yet discussions remained of qualitative nature or addressed only specific aspects quantitatively underlying the concept. The purpose of this paper is to develop a conceptual model identifying key factors determining strategic flexibility. Once quantified, the model provides firms a profile of each strategic option towards the company vision. Design/methodology/approach The paper reviews existing and synthesises prior contributions into a conceptual model of strategic flexibility. Based on semi-structured interviews and value mapping, the model is applied using three case studies from the automotive industry. Findings A total of three main findings were made. First, the concept of strategic flexibility has a simple logic that aligns itself to a variety of automotive companies and visions. However, underlying this remit is an interplay of variables. Previous studies remain fragmented and have only addressed a subset of variables. Second, these variables can be grouped into three dimensions of strategic flexibility – product, process and customer – to convey a holistic understanding of strategic flexibility and its key determinants. Third, due to the uncertainty and complexity involved, depending on the firm and industry characteristics, there cannot be a one-fits-all configuration of the strategic flexibility conceptualisation. Research limitations/implications A variety of variables requires consideration to offer a balanced view of all three dimensions of strategic flexibility. Hence, the case studies remain at a necessarily high level. Practical implications The paper offers guidance for management on how to align their firm strategy to product and process contingency factors to satisfy customer needs in line with their company vision. Originality/value The paper aims to elevate a discussion that previously remained fragmented and mainly descriptive.

scholarly journals INNOVATION STAGES AND ORGANIZATIONAL RESOURCES AT MIDSIZED COMPANIES IN BRAZIL DOI:10.7444/fsrj.v4i2.123

2012 ◽  
Vol 4 (2) ◽  
pp. 217-247
Author(s):  
Priscila Rezende Costa ◽  
Geciane Silveira Porto
Keyword(s):  
Organizational Innovation ◽  
Process Development ◽  
Innovation Process ◽  
Primary Data ◽  
Organizational Resources ◽  
Structured Interviews ◽  
Economic Sectors ◽  
Sequential Method ◽  
Organizational Resource ◽  
Product And Process

The structuring of innovation stages and analysis of organizational resources that catalyze innovative solutions is not only essential to the understanding of innovative behavior at midsized companies, but also to the raising of issues that may be of use when ideating public policies in support of innovation at midsized Brazilian companies. Given this framework, the purpose of this study is to analyze the status of innovation at midsized companies in Brazil. This was a triangular research that adopted the lifting sequential method effectively covering a sample made up of 50 mid-sized companies, scattered throughout 12 different economic sectors. Primary and secondary data were employed in the study. This was respectively collected via semi-structured interviews with managers and directors over the phone or via Skype and from journals, conference proceedings, journals and databases. During primary data collection, interviewers examined interviewee responses (content analysis) and subsequently defined corporate scores for each type of organizational resource using a 5-point scale, whereby 1 represented the highest level of organizational resource incipient application/presence, 3 an intermediate level and 5 the highest. Field research results (descriptive and multivariate analysis of data) revealed that the innovative profile of studied midsized companies is characterized by the intermediate stage in terms of product and processes innovation and by the embryonic stage when considering organizational innovation. This generally indicates that for product and process innovation, the prevailing strategy is technological differentiation and product and process development, whilst typically the innovation process is both mixed and closed. In as much as organizational innovation is concerned, core strategies include conducting technological benchmarks and monitoring market trends, whilst the innovation process is linear and non-systematic.

Information Modeling for Sustainable Manufacturing Assessment

2014 ◽  
Author(s):  
Haoqi Wang ◽  
Xu Zhang ◽  
Chao Liang ◽  
Qing Zhang
Keyword(s):  
Process Parameters ◽  
Sustainability Assessment ◽  
Process Development ◽  
Sustainable Manufacturing ◽  
Information Modeling ◽  
Machining Process ◽  
Assessment Process ◽  
Resource Information ◽  
Information Models ◽  
Product And Process

For sustainable manufacturing, energy consumption, air and waste emission, and environmental impact of product and process are analyzed in product and process development. The sustainability assessment is realized based on complete, structured information models of product, process and manufacturing resources, which are proposed in this paper. After analyzing the process of unit assembly and machining, two information models of unit assembly operation and unit machining process are given in UML representation. Besides the basic process parameters, the sustainable manufacturing related information such material consumption, energy usage, wastes and greenhouse air emission are also considered in the models. The manufacturing resource mode is core model to relate process and sustainability indicators. The resource information model of machining tool is proposed with process parameters and unit data of indictors. A sustainability assessment process is given in the end.

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